Method and instruments for assembling a femoral orthopaedic prosthesis

ABSTRACT

A method and instruments to assemble a femoral orthopaedic prosthesis is disclosed. The system may also include prosthetic trial components, which may be used to size and select the components of the orthopaedic prosthesis. The system may include components of the orthopaedic prosthesis such as, for example, a prosthetic femoral component, a prosthetic tibial component, a prosthetic stem component, and a prosthetic sleeve component.

CROSS-REFERENCE

Cross-reference is made to U.S. patent application Ser. No. 15/710,311entitled “Orthopaedic System and Method for Assembling ProstheticComponents,” and U.S. patent application Ser. No. 15/710,348 entitled“Method and Instruments for Assembling an Orthopaedic Prosthesis,” whichare filed on the same day as this application and are expresslyincorporated into this application by reference.

TECHNICAL FIELD

The present disclosure relates generally to orthopaedic instruments foruse in the performance of an orthopaedic joint replacement procedure,and, more particularly, to orthopaedic surgical instruments for use inthe performance of a knee replacement procedure.

BACKGROUND

Joint arthroplasty is a well-known surgical procedure by which adiseased and/or damaged natural joint is replaced by a prosthetic joint.For example, in a total knee arthroplasty surgical procedure, apatient's natural knee joint is partially or totally replaced by aprosthetic knee joint or knee prosthesis. A typical knee prosthesisincludes multiple prosthetic components, including a tibial tray, afemoral component, and a polymer insert or bearing positioned betweenthe tibial tray and the femoral component. The tibial tray generallyincludes a plate having a stem extending distally therefrom, and thefemoral component generally includes a pair of spaced apart condylarelements, which include surfaces that articulate with correspondingsurfaces of the polymer bearing. The stem of the tibial tray isconfigured to be implanted in a surgically-prepared medullary canal ofthe patient's tibia, and the femoral component is configured to becoupled to a surgically-prepared distal end of a patient's femur

From time-to-time, a revision knee surgery may need to be performed on apatient. In such a revision knee surgery, the previously-implanted kneeprosthesis is surgically removed and a replacement knee prosthesis isimplanted. In some revision knee surgeries, all of the components of thepreviously-implanted knee prosthesis, including, for example, the tibialtray, the femoral component, and the polymer bearing, may be surgicallyremoved. In other revision knee surgeries, only part of thepreviously-implanted knee prosthesis may be removed and replaced.

During any knee surgery, the orthopaedic surgeon typically uses avariety of different orthopaedic surgical instruments such as, forexample, cutting blocks, reamers, drill guides, and other surgicalinstruments to prepare the patient's bones to receive the kneeprosthesis. The surgeon may also utilize orthopaedic surgicalinstruments such as prosthetic trial components to size and select theappropriate prosthetic components. Such prosthetic trial components areshaped to match the size and shape as their corresponding prostheticcomponents but are not configured to be permanently implanted into thepatient's bones. Instead, prosthetic trial components may be temporarilyattached during surgery to the patient's bones in place of theprosthetic components to evaluate fit, range of motion, and otheraspects of the patient's joint and assist the surgeon in selecting theprosthetic components of the orthopaedic prosthesis for implantation.

SUMMARY

According to one aspect of the disclosure, an orthopaedic system andmethod for replacing a patient's knee joint is disclosed. The systemincludes the surgical instruments used to assemble an orthopaedicprosthesis. In some embodiments, the system may also include prosthetictrial components, which may be used to size and select the components ofthe orthopaedic prosthesis. The system may include components of theorthopaedic prosthesis such as, for example, a prosthetic femoralcomponent, a prosthetic tibial component, a prosthetic stem component,and a prosthetic sleeve component.

The surgical instruments of the orthopaedic system may include aninstrument base configured to receive a prosthetic trial carrier. Thetrial carrier may be configured to mount a prosthetic trial component tothe instrument base. It should be appreciated that the system mayinclude a number of prosthetic trial carriers, each of which isconfigured to receive a different configuration of prosthetic trialcomponent. In some embodiments, the prosthetic trial componentconfigurations may include a femoral trial component having a size andshape corresponding to a size and shape of a prosthetic femoralcomponent, a tibial trial component having a size and shapecorresponding to a size and shape of a prosthetic tibial component, anda stem trial component having a size and shape corresponding to a sizeand shape of a prosthetic stem.

In some embodiments, the instrument base may be configured to receive aprosthetic component carrier, which is configured to mount a prostheticcomponent to the instrument base. It should be appreciated that thesystem may include a number of prosthetic component carriers, each ofwhich is configured to receive a different configuration of prostheticcomponent. It should be appreciated that in some embodiments the samecarrier may be configured to selectively mount the prosthetic trialcomponent and the corresponding prosthetic component to the instrumentbase.

The surgical instruments of the orthopaedic system may include astabilizing or support arm configured to be coupled to the instrumentbase. The support arm may be configured to engage a portion of aprosthetic trial component and/or a portion of a prosthetic componentduring assembly to retain the prosthetic trial or prosthetic componentin position during assembly.

In some embodiments, the surgical instrument system may further comprisea wrench including an open slot sized to receive a femoral sleeve. Theopen slot may be defined by a plurality of surfaces of the wrench. Thewrench may also include a plurality of lobes extending from the surfacesinto the open slot. Each lobe may be shaped to engage a surface of thefemoral sleeve.

According another aspect of the disclosure, a surgical instrument systemfor selecting and assembling an orthopaedic prosthesis for a patient'sknee joint is disclosed. The surgical instrument system comprises a baseincluding a mounting platform, a first carrier including a mountingblock configured to be selectively positioned on the mounting platform,and a second carrier configured to be selectively positioned on themounting platform in place of the first carrier. The first carrierincludes a post extending at a non-orthogonal angle relative to themounting block, and the post includes a distal end that is sized to bereceived in a passageway of a prosthetic femoral component. The secondcarrier includes a first clamp plate and a second clamp plate that aremoveable to grip a prosthetic tibial component between the first clampplate and the second clamp plate.

In some embodiments, the surgical instrument system may further comprisea third carrier configured to mount a femoral trial component to thebase. The third carrier may include a mounting block configured to beselectively positioned on the mounting platform in place of the firstcarrier and the second carrier. The third carrier may further include apost extending at an orthogonal angle relative to the mounting block toa distal end. The distal end of the post of the third carrier mayinclude planar end surface and a pin extending from the end surface thatis sized to be received in a pocket of a femoral trial componentcorresponding to the prosthetic femoral component. In some embodiments,the pin may be configured to be received in a fastener of the prostheticfemoral component.

In some embodiments, the first carrier may further include a pair ofwalls connected to the post and extending outwardly from the mountingblock. The walls may be sized to be received in the intercondylar notchof the prosthetic femoral component. Additionally, in some embodiments,the third carrier may also include a pair of walls connected to the postand extending outwardly from the mounting block. The walls may be sizedto be received in the intercondylar notch of the femoral trialcomponent.

It should be appreciated that in some embodiments the surgicalinstrument system may further comprise a shim having a channel extendingalong a first axis and a thickness defined along a second axis extendingorthogonal to the first axis. The thickness of the shim may correspondto a width of the intercondylar notch of the prosthetic femoralcomponent and/or the femoral trial component. The channel may be sizedto receive each wall of the pair of walls of the first carrier and/orthe third carrier to selectively mount the shim on each wall.

Additionally, in some embodiments, the shim may include an opening and apair of side surfaces that extend inwardly from the opening to a basesurface. The pair of side surfaces and the base surface may cooperate todefine the channel in the shim. The shim may further include a groovethat is defined in one side surface of the pair of side surfaces andextends along the first axis. In some embodiments, each wall of the pairof walls may include a rib extending outwardly from a first planarsurface. The rib of each wall may be sized to be positioned in thegroove of the shim to permit the shim to be mounted in only a singleorientation on each wall. In some embodiments, the rib of one wall mayextend in the same direction as the rib of the other wall.

In some embodiments, the shim may be one shim of a plurality of shims.Each shim may have a different thickness from the other shims of theplurality of shims, and each thickness may correspond to a width ofintercondylar notch of one of a plurality of prosthetic femoralcomponents.

As discussed above, the surgical instrument system includes a secondcarrier configured to receive a prosthetic tibial component. In someembodiments, the second carrier may include a screw-type mechanism tomove the second clamp plate and the first clamp plate. One of the firstclamp plate and the second clamp plate of the second carrier may includea concave curved wall shaped to engage a convex curved anterior wall ofthe prosthetic tibial component. The other of the first clamp plate andthe second clamp plate may include a convex curved wall that ispositioned between, and connected to, a pair of concave curved walls.The convex curved wall and the pair of concave curved walls may beshaped to engage a posterior wall of the prosthetic tibial component.

In some embodiments, the second clamp plate of the second carrier mayinclude a rear slot sized to receive a posterior buttress of theprosthetic tibial component and a forward slot sized to receive ananterior buttress of the prosthetic tibial component.

In some embodiments, the base of the surgical instrument system mayinclude a stationary housing, and the mounting platform may berotatively coupled to the stationary housing to permit the mountingplatform to rotate 360 degrees relative to the stationary housing abouta vertical axis. In some embodiments, the base may further include alocking clutch operable to prevent the mounting platform from rotatingrelative to the stationary housing.

In some embodiments, the surgical instrument system may further comprisea support or stabilizer arm positioned above the base. The support armmay be attached to the stationary housing. Additionally, the support armmay be moveable in a horizontal plane relative to the mounting platform.

According to another aspect of the disclosure, a surgical instrumentsystem for selecting and assembling an orthopaedic prosthesis for apatient's knee joint comprises a base including a stationary housing, amounting platform that is rotatively coupled to the stationary housingto permit the mounting platform to rotate 360 degrees about a verticalaxis extending through the stationary housing, and a locking clutchoperable to prevent the mounting platform from rotating relative to thestationary housing. The surgical instrument system also comprises asupport arm removably coupled to the stationary housing. The support armis moveable in a horizontal plane relative to the vertical axis. Thesurgical instrument system further comprises a plurality of prosthetictrial carriers configured to be separately coupled to the mountingplatform to rotate with the mounting platform. Each prosthetic trialcarrier is configured to receive a prosthetic trial component having ashape and size corresponding to a prosthetic component of theorthopaedic prosthesis.

In some embodiments, the support arm may include an elongated bodypositioned in the horizontal plane, a first shaft positioned in thehorizontal plane and extending outwardly from the elongated body to aproximal tip, and a second shaft extending outwardly from the elongatedbody parallel to the first shaft to a proximal tip. A channel may bedefined between the proximal tips of the first shaft and the secondshaft. The channel is sized to receive a portion of a prosthetic trialcomponent positioned on one of the prosthetic trial carrier when theprosthetic trial carrier is coupled to the mounting platform.Additionally, in some embodiments, the surgical instrument system mayfurther comprise a user-operated knob operable to move the first shafttoward the second shaft to decrease a width of the channel.

In some embodiments, the mounting platform of the base may include apair of upwardly-extending pins. Each prosthetic trial carrier mayinclude a pair of apertures sized to separately receive theupwardly-extending pins. Additionally, in some embodiments, oneupwardly-extending pin has a different configuration (e.g., size and/orshape) from the other upwardly-extending pin such that the prosthetictrial carrier may be mounted in only a single orientation on themounting platform.

In some embodiments, the surgical instrument system may further comprisea femoral trial component configured to be mounted on at least one ofthe prosthetic trial carriers. The femoral trial component may include apair of convexly curved condyle surfaces. The system may also include anadaptor component configured to be secured to a proximal end of thefemoral trial component, and a stem trial component configured to besecured to a proximal end of the adaptor. The channel of the support armmay be sized to receive the adaptor component.

In some embodiments, the system may comprise a shim having a channelextending along a first axis and a thickness defined along a second axisextending orthogonal to the first axis. The thickness of the shim maycorrespond to a width of the intercondylar notch of the femoral trialcomponent, and the channel may be sized to receive a wall of the atleast one of the prosthetic trial carriers to permit the shim to bemounted on the prosthetic trial carrier.

In some embodiments, the adaptor component may include a visual indiciapositioned to face the elongated body of the support arm when theadaptor component is received in the channel of the support arm.

According to another aspect, the surgical instrument system forassembling an orthopaedic prosthesis for a patient's knee jointcomprises a base including a stationary housing, and a mounting platformthat is rotatively coupled to the stationary housing to permit themounting platform to rotate 360 degrees about a vertical axis extendingthrough the stationary housing. The surgical instrument system alsocomprises a support arm removably coupled to the stationary housing. Thesupport arm is moveable in a horizontal plane relative to the verticalaxis. The surgical instrument system further comprises a prostheticcomponent carrier configured to be coupled to the mounting platform torotate with the mounting platform. The prosthetic component carrier isconfigured to receive a prosthetic component of the orthopaedicprosthesis.

In some embodiments, the base may further include a locking clutchoperable to prevent the mounting platform from rotating relative to thestationary housing.

In some embodiments, the adaptor component may include a visual indiciapositioned to face the elongated body of the support arm when theadaptor component is received in the channel of the support arm.

In some embodiments, the prosthetic component carrier may be one of aplurality of prosthetic component carriers. Each prosthetic componentcarrier may be configured to receive a different configuration ofprosthetic component. It should be appreciated that the configurationsof prosthetic components may include a prosthetic femoral component orprosthetic tibial component.

According to another aspect of the disclosure, the orthopaedic systemmay include any of the surgical instrument systems described above. Asdescribed above, the orthopaedic system may also include the prostheticcomponents that form the orthopaedic prosthesis and the prosthetic trialcomponents corresponding to the prosthetic components.

According to another aspect, a method of assembling an orthopaedicprosthesis is disclosed. The method comprises aligning a tibial trialconstruct with a surgical instrument that includes a mounting platformand a stabilizer arm. The tibial trial construct comprises a base trialthat defines a first axis and an offset adaptor trial that defines asecond axis that is offset from the first axis. The method alsocomprises positioning the tibial trial construct on the mountingplatform, rotating the mounting platform to position the first axis andthe second axis in a plane extending vertically through the stabilizerarm, advancing the stabilizer arm along the vertically-extending planeto engage the stabilizer arm with the tibial trial construct, andlocking the mounting platform to prevent rotation relative to thestabilizer arm. The method further comprises positioning a tibialprosthetic component on the mounting platform after removing the tibialtrial construct such that a third axis defined by a distal post of thetibial prosthetic component is positioned in the plane, and positioninga tibial offset adaptor on the distal post. The tibial offset adaptorincludes a distal end that defines a fourth axis that is offset from thethird axis. The method comprises rotating the distal end of the tibialoffset adaptor to position the fourth axis in the vertically-extendingplane, and securing the tibial offset adaptor to the tibial prostheticcomponent with the third axis and the fourth axis positioned in theplane.

In some embodiments, the method may further comprise attaching a carrierto the mounting platform. The step of positioning the tibial trialconstruct on the mounting platform may comprise positioning the tibialtrial construct on the carrier, and advancing a first clamp plate of thecarrier into engagement with the base trial of the tibial trialconstruct to secure the base trial between the first clamp plate and asecond clamp plate of the carrier.

Additionally, in some embodiments, the step of positioning the tibialprosthetic component on the mounting platform after removing the tibialtrial construct may include positioning the tibial prosthetic componenton the carrier, and advancing the first clamp plate into engagement withthe tibial prosthetic component to secure the tibial prostheticcomponent between the first clamp plate and the second clamp plate.

In some embodiments, the method may further comprise securing a stemcomponent to the distal end of the tibial offset adaptor. The method mayalso comprise advancing the stabilizer arm along thevertically-extending plane to engage the stabilizer arm with the distalend of the tibial offset adaptor after rotating the distal end of thetibial offset adaptor to position the third axis in thevertically-extending plane.

Additionally, in some embodiments, the step of advancing the stabilizerarm along the vertically-extending plane to engage the stabilizer armwith the distal end of the tibial offset adaptor may include positioningthe distal end of the tibial offset adaptor in a channel defined in theproximal tip of the stabilizer arm.

In some embodiments, the step of advancing the stabilizer arm along thevertically-extending plane to engage the stabilizer arm with the offsetadaptor trial may include positioning the offset trial in the channeldefined in the stabilizer arm.

Additionally, in some embodiments, the method may further comprisesecuring the offset adaptor trial in the proximal tip of the stabilizerarm before locking the mounting platform to prevent rotation relative tothe stabilizer arm.

In some embodiments, the method may further comprise aligning a visualmarking on the offset adaptor trial with an alignment window defined inthe stabilizer arm. Additionally, in some embodiments, the step ofadvancing the stabilizer arm along the vertically-extending plane toengage the stabilizer arm with the offset adaptor trial further mayinclude aligning chamfered end surfaces of the proximal tip with asloped or tapered surface of the offset trial.

According to another aspect, a method of assembling an orthopaedicprosthesis comprises rotating a mounting platform of a surgicalinstrument about a vertically-extending axis, attaching a carrier to themounting platform, and positioning a first tibial prosthetic componenton the carrier. The first tibial prosthetic component includes a tibialtray and a post extending from the tibial tray. The method furthercomprises advancing a first clamp plate of the carrier into engagementwith the tibial tray to secure the tibial tray between the first clampplate and a second clamp plate of the carrier, and securing a secondtibial prosthetic component to the post of the first tibial prostheticcomponent.

In some embodiments, the step of securing the second tibial prostheticcomponent to the post of the first tibial prosthetic component mayinclude sliding the second tibial prosthetic component along a taperedouter surface of the post to secure the second tibial prostheticcomponent to the post. The second tibial prosthetic component mayinclude a stepped outer surface.

In some embodiments, the step of securing the second tibial prostheticcomponent to the post of the first tibial prosthetic component furthermay include attaching a first end of an impactor to a distal end of thesecond tibial prosthetic component and applying force to a second end ofthe impactor.

In some embodiments, the method may further comprise selecting a tibialtrial construct including a base trial and a tibial sleeve trial securedto the base trial and including a stepped outer surface corresponding tothe stepped outer surface of the second tibial prosthetic component, androtating the second tibial prosthetic component on the post of the firsttibial prosthetic component to orient the second tibial prostheticcomponent based on the orientation of the sleeve trial relative to thebase trial.

In some embodiments, the post of the first tibial prosthetic componentmay define a first axis, and the step of securing the second tibialprosthetic component to the post of the first tibial prostheticcomponent may include rotating a distal end of the second tibialprosthetic component to position a second axis defined by the distal endin a vertically-extending plane, and securing the second tibialprosthetic component to the post of the first tibial prostheticcomponent with the first axis and the second axis positioned in thevertically-extending plane.

In some embodiments, the method may further comprise advancing astabilizer arm of the surgical instrument along the vertically-extendingplane to position the stabilizer arm over the distal end of the secondtibial prosthetic component and securing the second tibial prostheticcomponent to the stabilizer arm. The stabilizer arm may have anelongated body that extends along the vertically-extending plane.

Additionally, in some embodiments, the step of advancing the stabilizerarm along the vertically-extending plane to position the stabilizer armover the distal end of the second tibial prosthetic component mayinclude positioning the distal end of the second tibial prostheticcomponent in a channel defined in a proximal tip of the stabilizer arm.

In some embodiments, the method may further comprise positioning atibial trial construct on the carrier. The tibial trial construct maycomprise a base trial that defines a base axis and an offset trial thatdefines a stem axis that is offset from the base axis. The method maycomprise advancing a stabilizer arm of the surgical instrument along thevertically-extending plane to engage the stabilizer arm with the tibialtrial construct, locking the mounting platform to prevent rotationrelative to the stabilizer arm, and removing the tibial trial constructfrom the carrier prior to positioning the first tibial prostheticcomponent on the carrier. The step of rotating the mounting platform ofthe surgical instrument may include rotating the carrier and the tibialtrial construct to position the base axis and the stem axis in thevertically-extending plane.

According to another aspect, a method of assembling an orthopaedicprosthesis comprises aligning a prosthetic trial assembly with asurgical instrument that includes a mounting platform and a stabilizerarm. The prosthetic trial assembly comprises a prosthetic trialcomponent that defines a first axis and an offset adaptor trial thatdefines a second axis that is offset from the first axis. The methodalso comprises positioning the prosthetic trial assembly on the mountingplatform, rotating the mounting platform to position the first axis andthe second axis in a plane extending vertically through the stabilizerarm, advancing the stabilizer arm along the vertically-extending planeto engage the stabilizer arm with the prosthetic trial assembly, lockingthe mounting platform to prevent rotation relative to the stabilizerarm, and positioning a prosthetic component on the mounting platformafter removing the prosthetic trial assembly such that a third axisdefined by a post of the prosthetic component is positioned in theplane. The prosthetic component has a size and a shape that matches asize and a shape of the prosthetic trial component. The method furthercomprises positioning on the post an offset adaptor including an endthat defines a fourth axis that is offset from the third axis by anamount equal to the offset of the first axis and the second axis,rotating the end of the offset adaptor to position the fourth axis inthe vertically-extending plane, and securing the offset adaptor to theprosthetic component with the third axis and the fourth axis positionedin the plane.

In some embodiments, the prosthetic component is a tibial prostheticcomponent and the prosthetic trial component is a tibial trial. In someembodiments, the prosthetic component is a femoral prosthetic componentand the prosthetic trial component is a femoral trial.

According another aspect of the disclosure, a method of assembling anorthopaedic prosthesis comprises aligning a femoral trial construct witha surgical instrument that includes a mounting platform and a stabilizerarm. The femoral trial construct comprises a post that defines a firstaxis and an offset adaptor trial that defines a second axis that isoffset from the first axis. The method also comprises positioning thefemoral trial construct on the mounting platform, rotating the mountingplatform to position the first axis and the second axis in a planeextending vertically through the stabilizer arm, advancing thestabilizer arm along the vertically-extending plane to engage thestabilizer arm with the femoral trial construct, and locking themounting platform to prevent rotation relative to the stabilizer arm.The method further comprises positioning a femoral prosthetic componenton the mounting platform after removing the femoral trial construct suchthat a third axis defined by a proximal post of the femoral prostheticcomponent is positioned in the plane, positioning a femoral offsetadaptor on the proximal post, the femoral offset adaptor including aproximal end that defines a fourth axis that is offset from the thirdaxis, and rotating the proximal end of the femoral offset adaptor toposition the fourth axis in the vertically-extending plane. The methodcomprises securing the femoral offset adaptor to the femoral prostheticcomponent with the third axis and the fourth axis positioned in theplane.

In some embodiments, the method may comprise attaching a carrier to themounting platform. The carrier may include a mounting plate and a postextending upwardly from the mounting plate. The step of positioning thefemoral trial construct on the mounting platform may comprise advancingthe femoral trial construct over the post to position the post in apassageway defined in the femoral trial construct.

Additionally, in some embodiments, the method may further compriseattaching to the carrier a shim sized to be positioned in anintercondylar notch defined in the femoral trial construct. The step ofpositioning the femoral trial construct on the mounting platform mayfurther comprise advancing the femoral trial construct over the shim toposition the shim in the intercondylar notch, and positioning thefemoral trial construct on the mounting platform may include preventinga pair of condyles of the femoral trial construct from engaging themounting plate of the carrier.

In some embodiments, the method may further comprise detaching thecarrier from mounting platform, and attaching a second carrier to themounting platform. The second carrier may include a second mountingplate and a second post extending upwardly from the second mountingplate. The second post may have a configuration different from theconfiguration of the first post. The method may also comprise attachingthe shim the second carrier.

Additionally, in some embodiments, the step of positioning the femoralprosthetic component on the mounting platform after removing the femoraltrial construct may include advancing the femoral prosthetic componentover the second post to position the second post in a passageway definedin the femoral prosthetic component, advancing the femoral prostheticcomponent over the shim to position the shim in an intercondylar notchof the femoral prosthetic component, and preventing a pair of condylesurfaces of the femoral prosthetic component from engaging the secondmounting platform of the second carrier.

In some embodiments, the method may comprise determining whether thefemoral trial construct includes one of a first femoral trial componentconfigured to be attached to a left femur and a second femoral trialcomponent configured to be attached to a right femur, and selecting afemoral prosthetic component based on whether the femoral trialconstruct includes the first femoral trial component or the secondfemoral trial component. The step of attaching the second carrier to themounting platform may include orienting the second carrier on themounting platform based on the selected femoral prosthetic component,and attaching the shim to the second carrier may include attaching theshim to one of a first wall of the second carrier positioned on a firstside of the second post and a second wall of the second carrierpositioned on a second side of the second post based on the selectedfemoral prosthetic component.

In some embodiments, the step of positioning the femoral prostheticcomponent on the mounting platform may include orienting the femoralprosthetic component such that the third axis extends at an orthogonalangle relative to the mounting platform. The femoral prostheticcomponent may include a pair of condyles and a box structure thatconnects the pair of condyles. The box structure may include a planarproximal surface that extends at a non-orthogonal angle relative to thethird axis.

In some embodiments, the method may further comprise securing a stemcomponent to the proximal end of the femoral offset adaptor. In someembodiments, the method may further comprise advancing the stabilizerarm along the vertically-extending plane to engage the stabilizer armwith the proximal end of the femoral offset adaptor after rotating theproximal end of the femoral offset adaptor to position the third axis inthe vertically-extending plane.

Additionally, in some embodiments, the step of advancing the stabilizerarm along the vertically-extending plane to engage the stabilizer armwith the proximal end of the femoral offset adaptor includes positioningthe proximal end of the femoral offset adaptor in a channel definedbetween a pair of proximal tips of the stabilizer arm. In someembodiments, the step of advancing the stabilizer arm along thevertically-extending plane to engage the stabilizer arm with the offsetadaptor trial includes positioning the offset trial in the channeldefined in the stabilizer arm.

In some embodiments, the method may further comprise securing the offsetadaptor trial in the proximal tip of the stabilizer arm before lockingthe mounting platform to prevent rotation relative to the stabilizerarm. Additionally, in some embodiments, the method may further comprisealigning a visual marking on the offset adaptor trial with an alignmentwindow defined in the stabilizer arm.

In some embodiments, the step of advancing the stabilizer arm along thevertically-extending plane to engage the stabilizer arm with the offsettrial may further include aligning a pair of chamfered end surfaces ofproximal tip with a sloped surface of the offset trial.

According to another aspect, a method of assembling an orthopaedicprosthesis comprises rotating a mounting platform of a surgicalinstrument about a vertically-extending axis, attaching a carrier to themounting platform, attaching a shim to the carrier, and positioning afirst femoral prosthetic component on the carrier. The first femoralprosthetic component including a pair of spaced apart condyles, anintercondylar notch sized to receive the shim, and a proximal post. Themethod may also comprise securing a second femoral prosthetic componentto the proximal post of the first femoral prosthetic component.

In some embodiments, the second femoral prosthetic component may includean elongated stem component. In some embodiments, the second femoralprosthetic component includes a prosthetic sleeve having a stepped outersurface.

The second femoral prosthetic component may include an offset adaptorand an elongated stem component configured to be attached to a proximalend of the offset adaptor. Additionally, in some embodiments, theproximal post of the first femoral prosthetic component defines a firstaxis, and the step of securing the second femoral prosthetic componentto the post of the first femoral prosthetic component may includerotating a proximal end of the offset adaptor to position a second axisdefined by the proximal end in a vertically-extending plane, andsecuring the offset adaptor to the proximal post of the first femoralprosthetic component with the first axis and the second axis positionedin the vertically-extending plane.

In some embodiments, the method may further advancing a stabilizer armof the surgical instrument along the vertically-extending plane toposition the stabilizer arm over the proximal end of the offset adaptorand securing the offset adaptor to the stabilizer arm.

According to another aspect, the surgical instrument system forassembling an orthopaedic prosthesis for a patient's knee jointcomprises a prosthetic component carrier configured to receive aprosthetic component of the orthopaedic prosthesis. In some embodiments,the prosthetic component carrier may include a mounting block and a postextending at a non-orthogonal angle relative to the mounting block. Thepost may include a distal end that is sized to be received in apassageway of a prosthetic femoral component.

In some embodiments, the prosthetic component carrier may include afirst clamp plate and a second clamp plate that are moveable to grip aprosthetic tibial component between the first clamp plate and the secondclamp plate.

In some embodiments, the surgical instrument system may further comprisea wrench including an open slot sized to receive a femoral sleeveconfigured to be coupled to the prosthetic femoral component. The openslot may be defined by a plurality of surfaces of the wrench. The wrenchmay also include a plurality of lobes extending from the surfaces intothe open slot. Each lobe may be shaped to engage a surface of thefemoral sleeve.

According to another aspect, the surgical instrument system forassembling an orthopaedic prosthesis for a patient's knee jointcomprises a trial component carrier configured to receive a trialcomponent corresponding to a prosthetic component of the orthopaedicprosthesis. In some embodiments, the trial component carrier may includea mounting block and a post extending at a non-orthogonal angle relativeto the mounting block. The post may include a distal end that is sizedto be received in a passageway of a femoral trial componentcorresponding to a femoral prosthetic component.

In some embodiments, the trial component carrier may include a firstclamp plate and a second clamp plate that are moveable to grip a tibialtrial component between the first clamp plate and the second clampplate.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description particularly refers to the following figures,in which:

FIG. 1 is an exploded perspective view of an orthopaedic surgicalinstrument system for assembling an implantable orthopaedic prosthesis;

FIG. 2 is an exploded perspective view of an instrument assembly base ofthe orthopaedic surgical instrument system of FIG. 1;

FIG. 3 is a bottom plan view showing the rotation locking mechanism ofthe instrument assembly base of FIG. 2 in an unlocked position;

FIG. 4 is a view similar to FIG. 3 showing the rotation lockingmechanism in a locked position;

FIG. 5 is an exploded perspective view of a stabilizer arm of theorthopaedic surgical instrument system of FIG. 1;

FIG. 6 is a perspective view of a femoral trial carrier and a shim ofthe orthopaedic surgical instrument system of FIG. 1;

FIG. 7 is a side elevation view of the femoral trial carrier of FIG. 6;

FIG. 8 is a perspective view of a femoral component carrier of theorthopaedic surgical instrument system of FIG. 1;

FIG. 9 is a side elevation view of the femoral prosthetic componentcarrier of FIG. 8;

FIG. 10 is a perspective view of a tibial component carrier of theorthopaedic surgical instrument system of FIG. 1;

FIG. 11 is a cross-sectional elevation view of the tibial componentcarrier taken along the line 11-11 in FIG. 10;

FIG. 12 is an exploded perspective view of a femoral prosthesis system;

FIG. 13 is a perspective view of a femoral sleeve component on aprosthetic femoral component;

FIG. 14 is an exploded perspective view of a femoral trial construct foruse in trialing the femoral prosthesis system of FIG. 12;

FIG. 15 is a perspective view of a femoral broach;

FIG. 16 is an exploded perspective view of a tibial prosthesis system;

FIG. 17 is an exploded perspective view of a tibial trial construct foruse in trialing the tibial prosthesis system of FIG. 16;

FIG. 18 is a perspective view of a sleeve impactor of the system of FIG.1;

FIG. 19 is a side elevation view of the sleeve impactor of FIG. 18;

FIG. 20 is the side elevation view opposite the view of FIG. 19; and

FIGS. 21-47 are illustrations of an exemplary technique for assemblingvarious orthopaedic prostheses using the instrument system of FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

While the concepts of the present disclosure are susceptible to variousmodifications and alternative forms, specific exemplary embodimentsthereof have been shown by way of example in the drawings and willherein be described in detail. It should be understood, however, thatthere is no intent to limit the concepts of the present disclosure tothe particular forms disclosed, but on the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention as defined by the appended claims.

Terms representing anatomical references, such as anterior, posterior,medial, lateral, superior, inferior, etcetera, may be used throughoutthe specification in reference to the orthopaedic implants or prosthesesand surgical instruments described herein as well as in reference to thepatient's natural anatomy. Such terms have well-understood meanings inboth the study of anatomy and the field of orthopaedics. Use of suchanatomical reference terms in the written description and claims isintended to be consistent with their well-understood meanings unlessnoted otherwise.

Referring now to FIG. 1, an orthopaedic surgical instrument system 10for use in selecting and assembling an orthopaedic prosthesis is shown.The surgical instrument system 10 includes an instrument base 12 and anumber of modular instruments 14 that are selectively attached to thebase to position a prosthetic femoral component 16 (see FIG. 12) or aprosthetic tibial component 18 (see FIG. 19) on the base 12. Asdescribed in greater detail below, some of the instruments 14 may beused to position a femoral trial component 20 (see FIG. 14) or a tibialtrial component 22 (see FIG. 20) on the base 12 to assist the surgeon inassembling the prosthetic components. In the illustrative embodiment,the instrument system 10, prosthetic components 16, 18, and trialcomponents 20, 22 form part of an orthopaedic system that may be used toreplace a patient's knee joint. Although only a single size of eachprosthetic component and each trial component is shown, it should beappreciated that the orthopaedic system may include multiple sizes ofprosthetic components and trial components to fit the needs of variouspatients.

The modular instruments 14 of the system 10 include a femoral trialcarrier 30 that is configured to mount the femoral trial component 20 onthe instrument base 12. The instruments 14 also include a prostheticfemoral component carrier 32 that is configured to mount the prostheticfemoral component 16 on the instrument base 12, and a tibial componentcarrier 34 that, in the illustrative embodiment, is configured to mounteither the prosthetic tibial component 18 or the tibial trial component22 to the base 12. Each of the carriers 30, 32, 34 are sized to receiveany size of prosthetic component or trial component in the orthopaedicsystem, as described in greater detail below. As shown in FIG. 1, themodular instruments 14 also include a stabilizing or support armassembly 36, which can be used with the carriers 30, 32, 34 duringprosthesis assembly.

The instrument base 12 includes a housing 40 configured to be positionedon a planar surface such as, for example, a table in an operating room.The instrument base 12 includes a platform 42 that is configured torotate relative to the housing 40 about an axis 38. The platform 42includes a pair of pins 44 that are sized to be selectively received ineach of the carriers 30, 32, 34 to orient the carriers 30, 32, 34 on theinstrument base 12.

As shown in FIG. 1, the platform 42 is positioned in a central section46 of the housing 40. The housing 40 also includes an elongated plate 48that extends outwardly from the central section 46 and an end plate 50that is positioned opposite from the elongated plate 48. A mounting post52 extends upwardly from an end 54 of the elongated plate 48 and isconfigured to receive the support arm assembly 36. The instrument base12 also includes a locking mechanism 56 that is positioned in the endplate 50. As described in greater detail below, the locking mechanism 56may be used to fix the platform 42 in a particular orientation about theaxis 38 relative to the housing 40.

Referring now to FIG. 2, the housing 40 includes a planar upper surface60, and the central section 46 of the instrument base 12 includes acavity 62 that is defined in the upper surface 60 and is sized toreceive the platform 42. The instrument base 12 includes a frame 64 thatis positioned at the bottom of the cavity 62 to support the platform 42.The platform 42 is attached to the housing 40 by a fastener plug 66,which extends through a central opening 68 defined in the platform 42and is received in a mounting pin 70 that extends upwardly from theframe 64 at the center of the cavity 62.

In the illustrative embodiment, the plug 66 includes a head plate 72 anda shaft 74 that extends downwardly from the head plate 72. The shaft 74is sized to be received in an aperture 76 defined in the mounting pin 70to secure the plug 66 to the housing 40. As shown in FIG. 2, theplatform 42 includes a disk 80 that has a planar upper surface 82, andthe central opening 68 extends through the upper surface 82 to a lowersurface 84 of the disk 80. A rim wall 88 extending into the centralopening 68 engages the head plate 72 of the plug 66 to retain theplatform 42 between the head plate 72 and the frame 64 of the housing40. In the illustrative embodiment, the instrument base 12 also includesa spacer ring 90 that is positioned between the rim wall 88 and themounting pin 70 to act as a bearing between the stationary pin 70 andthe rotating platform 42. As shown in FIG. 2, the axis 38 about whichthe platform 42 is rotated extends through center of the central opening68.

The disk 80 includes an outer annular wall 100 that extends from theupper surface 82 to the lower surface 84. The disk 80 also includes aplurality of gear teeth 102 that are defined in the outer wall 100around the circumference of the disk 80. As described in greater detailbelow, the gear teeth 102 interact with the locking mechanism 56 to fixthe mounting platform 42 in position relative to the housing 40. Themounting platform 42, plug 66, and spacer ring 90, like the housing 40,are formed from materials that may be autoclaved such as, for example,stainless steel.

As described above, the mounting platform 42 also includes a pair ofpins 44 that are sized to be selectively received in each of thecarriers 30, 32, 34 to orient the carriers 30, 32, 34 on the instrumentbase 12. In the illustrative embodiment, the pins 44 extend upwardlyfrom the upper surface 82 of the disk 80. The pins 44 include agenerally cylindrical pin 104 that is positioned on one side of theopening 68 and a polygonal pin 106 that is positioned on the oppositeside of the opening 68. The polygonal pin 106 has a width that issmaller than the diameter of the cylindrical pin 104. It should beappreciated that in other embodiments the pins may take differentgeometric shapes and may be sized differently to orient the carriers.

The platform 42 includes visual indicia 110 and the housing 40 includesvisual indicia 112, which may be used during surgery to confirm theproper orientation and position of the instruments. In the illustrativeembodiment, the indicia 110 on the platform 42 include arrows andletters (“L” corresponding to “Left” and “R” corresponding to “Right”).The indicia 112 on the housing 40 include indicator lines, and thearrows of indicia 110 may be aligned with the indicator lines toindicate the orientation and position of the instruments. In otherembodiments, the indicia 110, 112 may include numbers or otherindicators.

As described above, the instrument base 12 also includes a mounting post52 that extends upwardly from an end 54 of the elongated plate 48. Themounting post 52 is configured to receive the support arm assembly 36.In the illustrative embodiment, the post 52 includes an upper end 120and an opening 122 that is defined in the upper end 120. A centralpassageway 124 sized to receive a mounting shaft 126 of the support armassembly 36 extends inwardly from the opening 122. The post 52 alsoincludes an alignment slot 128 that extends from the upper end 120 andopens into the passageway 124. The alignment slot 128 is sized toreceive an alignment tab 130 of the support arm assembly 36 and definesa twisting path for the alignment tab 130 that causes the support armassembly 36 to rotate from an initial, insertion position to a final,assembled relative to the platform 42. In the final assembled position,the alignment tab 130 is retained in a lower pocket 132 of the alignmentslot 128.

As described above, the instrument base 12 also includes a rotationlocking mechanism 56 that is positioned in the end plate 50. Each of thecomponents of the mechanism 56 is formed from a material such as, forexample, stainless steel, which may be autoclaved so that the base 12may be cleaned between surgeries. The locking mechanism 56 includes auser-operated knob 140 that is received in a cavity 142 defined in theupper surface 60 of the base housing 40. The knob 140 is operable torotate relative to the base housing 40 and includes a main plate 144 andan elongated grip 146 that extends upwardly from the main plate 144. Inthe illustrative embodiment, the elongated grip 146 includes a pointedtip 148 that indicates whether the knob 140 is in a locked position orunlocked position. The pointed tip 148 may point to indicia on thehousing 40 to indicate the locked or unlocked positions. The knob 140also includes an oblong base 152 that extends downwardly from the mainplate 144 and is received in the cavity 142.

In the illustrative embodiment, the base housing 40 includes a frame 154that is positioned at the bottom of the cavity 142 to support the base152 of the knob 140. The knob 140 is attached to the base housing 40 viaa fastener 156, which extends through the frame 154. The fastener 156extends through a cylindrical mounting pin 158 and is received in theoblong base 152 of the knob 140. As shown in FIG. 3, the fastener 156 ispositioned in a bore 160 that is offset from the center of the oblongbase 152. The bore 160 defines the axis of rotation 166 of the knob 140.The oblong base 152 also includes an arced channel or groove 162 thatreceives a guide pin 164 secured to the frame 154. The pin 164 interactswith the groove 162 to limit the rotational movement of the knob 140, asdescribed in greater detail below.

Returning to FIG. 2, the locking mechanism 56 also includes a clutch 170that selectively engages the gear teeth 102 of the platform 42. Theclutch 170 includes a mounting body 172 and a pair of arms 174, 176 thatextend outwardly from the mounting body 172. In the illustrativeembodiment, a central bore 178 extends through the mounting body 172 andis sized to receive a shaft 180 of a mounting peg 182. The shaft 180includes a threaded distal end 184 that is threaded into an opening 186defined in the base housing 40 to secure the mounting peg 182 to thehousing 40. The mounting body 172 is retained between the head plate 188of the mounting peg 182 and an inner surface 190 of the housing 40. Thecentral bore 178 defines an axis of rotation 192 of the clutch 170.

The arm 174 of the clutch 170 extends from the mounting body 172 to atip 200. The tip 200 includes a plurality of teeth 202 that are sizedand shaped to interlock with the gear teeth 102 of the platform 42. Asshown in FIG. 2, an elongated opening 204 is defined between the frame154 and the inner surface 190 of the housing 40. The tip 200 extendsthrough the opening 204 to engage the gear teeth 102 as the clutch 170is rotated about the axis 192.

The other arm 176 of the clutch 170 extends from the mounting body 172to a follower housing 210 sized to be positioned between the frame 154and the main plate 144 of the knob 140. The follower housing 210includes an upper opening 212 and an inner wall 214 that extendsinwardly from the opening 212 to define an oblong slot 216 sized toreceive the oblong base 152 of the knob 140. As shown in FIG. 3, theoblong slot 216 is larger than the oblong base 152. The inner wall 214of the follower housing 210 includes a follower surface 220, and theoblong base 152 includes a cam surface 222 configured to selectivelyengage the follower surface 220 to rotate the clutch 170 about the axis192.

To lock the platform 42 in an orientation relative to the base housing40, a surgeon or other user may grasp the grip 146 of the knob 140 androtate the knob 140 in the direction indicated by arrow 224 in FIG. 3.As the knob 140 is rotated, a section 226 of the cam surface 222 of theoblong base 152 that is initially out of contact with the followersurface 220 is advanced into engagement with the follower surface 220.As the section 226 of the cam surface 222 engages the follower surface220, the clutch 170 is rotated about the axis 192 as indicated by arrow232 to advance the teeth 202 into engagement with the teeth 102 of theplatform 42, thereby locking the platform 42 in position relative to thehousing 40. As shown in FIG. 4, the guide pin 164 moves from one end ofthe groove 162 to the opposite end of the groove 162 and preventsexcessive rotation of the knob 140 (and hence the clutch 170).

To unlock the platform 42, the surgeon or other user may grasp the grip146 of the knob 140 and rotate the knob 140 in the direction indicatedby arrow 228 in FIG. 4. As the knob 140 is rotated, a section 230 of thecam surface 222 of the oblong base 152 that is out of contact with thefollower surface 220 is advanced into engagement with the followersurface 220. As the section 230 of the cam surface 222 engages thefollower surface 220, the clutch 170 is rotated about the axis 192 asindicated by arrow 234 to disengage the teeth 202 from the teeth 102 ofthe platform 42.

Returning to FIG. 1, the system 10 also includes the support armassembly 36, which is configured to attached to the instrument base 12.The support arm assembly 36 includes the mounting shaft 126 that extendsfrom a lower end 250, which is sized to be positioned in mounting post52 to an upper end 252. A bracket 254 is secured to the upper end 252,and the bracket 254 includes a central passageway 256 sized to receivean elongated arm 258 of the support arm assembly 36. The elongated arm258 extends along a longitudinal axis 260 from a handle end 262 to a tip264. As described in greater detail below, the elongated arm 258 isconfigured to slide within the passageway 256 along the axis 260 toadvance the tip 264 toward and away from the axis 38 of the instrumentbase 12. Additionally, the longitudinal axis 260 and the axis 38 arepositioned in (and define) a vertically-extending orientation plane 270(see FIG. 21), which is described in greater detail below.

Referring now to FIG. 5, the elongated arm 258 includes a main body 272that extends from the handle end 262. In the illustrative embodiment, ahandle grip 274 is attached to the main body 272 at the handle end 262via a pair of pins 276. The elongated arm 258 also includes a pair ofshafts 278, 280 that extend from an end of the main body 272 to the tip264 of the elongated arm 258. The shafts 278, 280 are spaced apart fromone another such that a channel 282 is defined between them. The channel282 is wider at its proximal end 288 at the tip 264 and narrower nearthe elongated arm 258. As described in greater detail below, the channel282 is sized to receive the offset adaptors of the trial componentassemblies and prosthetic component assemblies.

Each shaft 278, 280 includes a chamfered end wall 284, which define thetip 264 of the elongated arm 258, and an inner wall 286 that faces theother shaft. The inner walls 286 of the shafts 278, 280 cooperate todefine the proximal end 288 of the channel 282.

In the illustrative embodiment, the support arm assembly 36 includes atightening mechanism 300 that may be operated to narrow the proximal end288 of the channel 282 by pulling the shafts 278, 280 closer together.The tightening mechanism 300 includes a user-operated knob 302 and anelongated shaft 304 extending from the knob 302. The elongated shaft 304extends through a bore (not shown) defined in the shaft 280 to athreaded end 306, which is received in a threaded bore 308 defined inthe shaft 278.

As shown in FIG. 5, the bracket 252 of the support arm assembly 36includes an upper housing 310 and a stem 312 that extends from the upperhousing 310. The stem 312 is sized to be received in a passageway 314defined in the mounting shaft 126. In the illustrative embodiment, thestem 312 is secured to the shaft 126 via a pin 316. The upper housing310 includes the central passageway 256 through which the elongated arm258 extends. It should be appreciated that each of the components of thesupport arm assembly 36 is formed from a material such as, for example,stainless steel, which may be autoclaved so that the support armassembly 36 may be cleaned between surgeries.

Returning to FIG. 1, the system 10 also includes a femoral trial carrier30, a prosthetic femoral component carrier 32, and a tibial componentcarrier 34 that are configured to be selectively mounted on the platform42 of the instrument base 12. In other words, each of the carriers 30,32, 34 is configured to be mounted on the platform 42 in place of any ofthe other carriers 30, 32, 34. Each of the carriers 30, 32, 34 includesa pair of orientation holes 320, 322 that are sized to receive the pins104, 106, respectively, of the platform 42 to orient and attach thecarriers 30, 32, 34 to the platform 42. In the illustrative embodiment,each of the orientation holes 320, 322 is cylindrical but theorientation hole 320 has a larger diameter than the orientation hole 322such that the carriers 30, 32, 34 are configured to mounted on theplatform 42 in only a single orientation. It should be appreciated thateach of the carriers 30, 32, 34 is formed from a material such as, forexample, stainless steel, which may be autoclaved so that the carriers30, 32, 34 may be cleaned between surgeries.

Referring now to FIG. 6, the femoral trial carrier 30 includes amounting block 330 and a post 332 that extends upwardly from themounting block 330. The mounting block 330 is elongated and extendsalong a longitudinal axis 334 from a longitudinal end 336 to itsopposite longitudinal end 338. The block 330 includes a planar bottomsurface 340 and a top surface 342 that is positioned opposite the bottomsurface 340. An outer wall 344 connects the top surface 342 to thebottom surface 340. In the illustrative embodiment, the outer wall 344has visual indicia 346 at each end 336, 338 to indicate the orientationof the mounting block 330. The visual indicia 346 includes letters inthe illustrative embodiment (“Left” on the end 336 and “Right” on theend 338).

The post 332 extends from the top surface 342 of the block 330 to anupper end 348. In the illustrative embodiment, the post 332 includes acylindrical outer surface 350, and an alignment pin 352 extendsoutwardly from the upper end 348. The alignment pin 352 is shaped to bereceived in a bore 732 (see FIG. 23) of the femoral trial component 20.As shown in FIGS. 6-7, the alignment pin 352 includes a rounded base 354and extends to a narrow tip 356. The post 332 extends along alongitudinal axis 360 extending through the tip 356. The axis 360 (andhence the post 332) extends at an orthogonal angle relative to the topsurface 342 of the block 330.

The femoral trial carrier 30 also includes a pair of walls 362, 364extending upward from the top surface 342 of the block 330 on oppositesides of the post 332. In the illustrative embodiment, the walls 362,364 extend at a non-orthogonal angle relative to the top surface 342.Each wall 362, 364 is connected to the post 332 and includes planarouter surfaces 366, 368 that extend to the ends 336, 338 of the carrier30. A rib 370 is formed on the outer surface 366 of each of the walls362, 364. As shown in FIG. 6, the ribs 370 extend parallel to thelongitudinal axis 334.

As described above, the carrier 30 includes a pair of orientation holes320, 322 that are sized to receive the pins 104, 106, respectively, ofthe platform 42 to orient and attach the carrier 30 to the platform 42.In the illustrative embodiment, the holes 320, 322 extend through theblock 330 and have upper openings positioned in a channel 372 defined inthe top surface 342 next to the walls 362, 364.

Referring now to FIG. 8, the prosthetic femoral component carrier 32includes a mounting block 430 and a post 432 that extends upwardly fromthe mounting block 430. The mounting block 430 is elongated and extendsalong a longitudinal axis 434 from a longitudinal end 436 to itsopposite longitudinal end 438. The block 430 includes a planar bottomsurface 440 and a top surface 442 that is positioned opposite the bottomsurface 440. An outer wall 444 connects the top surface 442 to thebottom surface 440. In the illustrative embodiment, the outer wall 444has visual indicia 446 at each end 436, 438 to indicate the orientationof the mounting block 430. The visual indicia 446 includes letters inthe illustrative embodiment (“Left” on the end 436 and “Right” on theend 438).

The post 432 extends from the top surface 442 of the block 430 to anupper end 448. In the illustrative embodiment, the post 432 includes acylindrical outer surface 450. The post 432 extends along a longitudinalaxis 460, and the upper end 448 is sized to be received in a bore 622(see FIG. 31) of the prosthetic femoral component 16. In theillustrative embodiment, the post 432 extends at a non-orthogonal anglerelative to the top surface 442 of the block 430, as shown in FIG. 9.

The femoral component carrier 32 also includes a pair of walls 462, 464extending upward from the top surface 442 of the block 430 on oppositesides of the post 432. In the illustrative embodiment, the walls 462,464 extend parallel to the post 432. Each wall 462, 464 is connected tothe post 432 and includes planar outer surfaces 466, 468 that extend tothe ends 436, 438 of the carrier 32. A rib 470 is formed on the outersurface 466 of each of the walls 462, 464. As shown in FIG. 8, the ribs470 extend parallel to the longitudinal axis 434.

As described above, the carrier 32 includes a pair of orientation holes320, 322 that are sized to receive the pins 104, 106, respectively, ofthe platform 42 to orient and attach the carrier 32 to the platform 42.In the illustrative embodiment, the holes 320, 322 extend through theblock 430 and have upper openings positioned in a channel 472 defined inthe top surface 442 next to the walls 462, 464.

As shown in FIG. 8, the walls 462, 464 include relief slots 474extending through the surfaces 466, 468 adjacent the post 432.Additionally, as shown in FIG. 9, the top surface 442 of the block 430includes a section 476 positioned opposite the rib 470 that extends froman inner edge 478 to an outer edge 480. The section 476 extends at anon-orthogonal angle relative to the bottom surface 440 such that theouter edge 480 is closer to the bottom surface 440 than the inner edge478.

Referring now to FIG. 10, the system 10 also includes the tibialcomponent carrier 34. As described above, the carrier 34 is configuredto mount either the prosthetic tibial component 18 or the tibial trialcomponent 22 to the base 12. The carrier 34 includes a mounting block500 and a pair of clamp plates 502, 504 that are movably coupled to themounting block 500. As described in greater detail below, the carrier 34also includes a screw-type drive mechanism 506 operable to move theclamp plates 502, 504 to grip a prosthetic tibial component 18 or atibial trial component 22 positioned on the plates 502, 504.

The mounting block 500 includes a base plate 510 and a pair of sidewalls 512 that extend upwardly from the base plate 510. Each side wall512 includes a planar upper surface 514. A channel 516 extending throughthe mounting block 500 is defined between the base plate 510 and theside walls 512. As shown in FIG. 10, a flange 518 extends inwardly fromeach side wall 512 into the channel 516 to support the clamp plates 502,504.

The clamp plate 502 of the carrier 34 includes an upper body 530positioned above the side walls 512 and a lower body 532 extendingdownwardly from the upper body 530. The lower body 532 is received inthe channel 516, and a pair of legs 534 extend outwardly from the lowerbody 532 to engage the lower surfaces of the flanges 518 of the mountingblock 500. As shown in FIG. 10, the flanges 518 are positioned inchannels 536 defined between the legs 534 and a planar lower surface 538of the upper body 530. The upper body 530 also includes a top surface540 that is positioned opposite the lower surface 538.

The clamp plate 502 includes a jaw 542 extending upwardly from the topsurface 540. The jaw 542 has a curved inner wall 544 that is shaped tomatch the curvature of an anterior wall section 934 of the prosthetictibial component 18 and the tibial trial component 22. The jaw 542 alsoincludes an engagement tab 546 that extends outwardly from the curvedinner wall 544.

As described above, the carrier 34 also includes a clamp plate 504 thatis positioned opposite the clamp plate 502. The clamp plate 504 includesan upper body 550 positioned above the side walls 512 and a lower body532 extending downwardly from the upper body 550. The lower body 532 hasa configuration that is identical in relevant aspects to the lower body532 of the clamp plate 502. The lower body 532 of the clamp plate 504 isreceived in the channel 516, and a pair of legs 534 extend outwardlyfrom the lower body 532 to engage the lower surfaces of the flanges 518of the mounting block 500.

The upper body 550 of the clamp plate 504 includes a top surface 552that is positioned opposite a lower surface 554. The clamp plate 504includes a pair of pads 556, 558 extending upwardly from the top surface552. As shown in FIG. 10, a Y-shaped channel 560 is defined between pads556, 558. The clamp plate 504 also includes a jaw 562 extending upwardlyfrom the top surface 552. The jaw 562 has a pair of curved concave innerwalls 564 and a curved convex inner wall 566 that is positioned betweenthe walls 564. The walls 564, 566 that are shaped to match the curvatureof posterior wall sections 936, 938 of the prosthetic tibial component18 and the tibial trial component 22. The jaw 562 also includesengagement tabs 568 that extend outwardly from the curved inner walls564.

As shown in FIG. 11, the carrier 34 includes a screw-type drivemechanism 506 that is operable to move the clamp plates 502, 504. In theillustrative embodiment, the mechanism 506 includes a threaded shaft 570that is received in a threaded bore 572 defined in the lower body 532 ofthe clamp plate 502. The mechanism 506 includes a threaded shaft 574that is received in a threaded bore 576 defined in the lower body 532 ofthe clamp plate 504. The mechanism 506 also includes a user-operatedknob 580 connected to an end of the threaded shaft 574.

The shafts 570, 574 are connected via a rod 582 that extends through abrace 584 of the mounting block 500. As shown in FIGS. 10-11, the brace584 extends from the side walls 512 of the mounting block 500 and ispositioned in the channel 516. A pair of spacer rings 590 extend fromthe rod 582 on each side of the brace 584 to attach the mechanism 506 tothe mounting block 500.

In use, a surgeon or other user may grasp the knob 580 and rotate theshafts 570, 574. The engagement between the shafts 570, 574 and thebores 572, 576 cause the clamp plates 502, 504 to advance along theshafts 570, 574. When the shafts 570, 574 are rotated clockwise, theclamp plates 502, 504 move toward one another; when the shafts 570, 574are rotated counter-clockwise, the clamp plates 502, 504 move apart.

As described above, the instrument system 10 is configured for use inselecting and assembling an orthopaedic prosthesis. In the illustrativeembodiment, the orthopaedic prosthesis includes the prosthetic femoralcomponent 16 shown in FIGS. 12-13 and the prosthetic tibial component 18shown in FIG. 16. Each of those components forms part of largerprosthesis systems that may include, for example, additional prostheticfemoral and tibial components of various sizes to fit the needs ofpatients with larger or smaller bones. The other prosthetic componentsmay also be sized and shaped to be fitted on either the patient's leftleg or the patient's right leg. Additionally, the systems may includeother prosthetic components that attach to, or used in conjunction with,the prosthetic femoral component 16 and/or the prosthetic tibialcomponent 18, as described in greater detail below.

Referring now to FIGS. 12-13, a femoral orthopaedic prosthesis system600 includes the prosthetic femoral component 16 that is configured tobe attached to a surgically-prepared distal end of a patient's femur.The femoral component 16 includes an anterior flange 602 and a pair ofcondyles 604, 606 extending posteriorly from the anterior flange 602. Anintercondylar notch 608 is defined between the pair of condyles 604,606. In the illustrative embodiment, the notch 608 is defined between apair of side walls 610 that extend from proximal surfaces 612 of theanterior flange 602 and condyles 604, 606. A proximal wall 614 extendsbetween the side walls 610 to enclose the proximal end of the notch 608.

The femoral component 16 also includes a post 616 that extends from theproximal wall 614. As shown in FIG. 12, the post 616 includes a proximalopening 618, and an inner wall 620 extends inwardly from the proximalopening 618 to define a bore 622 extending through the post 616 and theproximal wall 614 of the femoral component 16. In the illustrativeembodiment, the inner wall 620 includes a threaded proximal section 624.The post 616 also includes a tapered outer surface 626 sized to receivea metaphyseal member such as, for example, a sleeve component 628 (seeFIG. 13).

In the illustrative embodiment, the post 616 extends along alongitudinal axis 630, and the proximal wall 614 of the femoralcomponent 16 includes a substantially planar surface 632. When thefemoral component 16 is viewed in a coronal plane, a non-orthogonalangle is defined between the axis 630 and the substantially planarsurface 632. It should be appreciated that the magnitude of the anglemay vary in various embodiments and based on the size and configurationof the prosthesis assembly.

As shown in FIG. 12, the prosthesis system 600 also includes a stemcomponent 640. The stem component 640 includes an elongated body 642that extends from a distal end 644 to a proximal tip 646. A plurality ofthreads 648 are defined on the distal end 644, which, in someconfigurations of the prosthesis assembly, may engage the threadedproximal section 624 of the post 616 or the threaded proximal section650 of the sleeve component 628 (see FIG. 13).

The prosthesis system 600 also includes an offset adaptor 660 that isconfigured to be secured to the femoral component 16 and the stemcomponent 640 to form an offset femoral prosthesis assembly 662. Theoffset adaptor 660 includes a body 664 that extends from a distal end666 to a proximal end 668 that is offset from the distal end 666, asshown in FIG. 12. The body 664 includes a threaded shaft 670 thatextends proximally from the distal end 666 to a rim wall 672. The body664 also includes a curved tapered surface 674 extends proximally fromthe rim wall 672. The threaded shaft 670 is configured to engage thethreaded proximal section 624 of the post 616 to attach the adaptor 660to the femoral component 16. The offset adaptor 660 also includes alocking nut 676 that is threaded onto the shaft 670, which may beoperated to secure the offset adaptor 660 to the femoral component 16,as described in greater detail below.

The body 664 also includes an opening 680 that is defined in theproximal end 668. A threaded inner wall 682 extends inwardly from theopening 680 to define a threaded bore 684 sized to receive the threadeddistal end 644 of the stem component 640. As shown in FIG. 12, theoffset adaptor 660 defines a proximal axis 686 that extends through thethreaded bore 684 and along the longitudinal axis of the stem component640. The offset adaptor 660 also defines a distal axis 688 that extendsthrough the threaded shaft 670 and is aligned with the longitudinal axis630 of the post 616 of the femoral component 16. The axes 686, 688extend parallel to, but are offset from, one another. In theillustrative embodiment, the body 664 is a single monolithic componentsuch that the distal end 666 and the proximal end 668 are fixed relativeto one another.

As shown in FIG. 13, the sleeve component 628 includes a stepped outerwall 690 that extends from a distal end 692 to a proximal end 694. Thecomponent 628 has an opening 696 defined in the proximal end 694 and aninner wall including the threaded proximal section 650 that extendsinwardly from the opening 696. The component 628 also has a distalopening (not shown) sized to receive the post 616. It should beappreciated that the distal opening is defined by a tapered innersurface that corresponds to the tapered outer surface 626 of the post616 such that the sleeve component 628 may be secured to the post 616via a taper lock.

As shown in FIG. 13, the stepped outer wall 690 of the sleeve component628 includes a porous section 700 configured to promote bone growth andsupport fixation of the sleeve component 628 in the patient's bone. Theouter wall 690 also includes a number of planar surfaces 702 at theproximal end 694 that are shaped to receive a wrench head 1264 (see FIG.37) to assist with assembly, as described in greater detail below. Thestem component 640, femoral component 16, and sleeve component 628 formpart of a femoral sleeve prosthesis assembly 704 that may be implantedin a patient's femur.

Referring now to FIGS. 14-15, a femoral trial system 710 includes thefemoral trial component 20 that is configured to be temporarily attachedto the distal end of a patient's femur to assist with the surgicalpreparation of the patient's femur to receive the prosthetic femoralcomponent 16. The femoral trial component 20 includes an anterior flange712 and a pair of condyles 714, 716 extending posteriorly from theanterior flange 712. An intercondylar notch 718 is defined between thepair of condyles 714, 716. In the illustrative embodiment, theconfigurations of the flange 712, the condyles 714, 716, and theintercondylar notch 718 match the configurations of the correspondingstructures in the prosthetic femoral component 16. It should beappreciated that in other embodiments the femoral trial component mayinclude one or more cutting guides that extend through the anteriorflange 712 and/or the condyles 714, 716.

In the illustrative embodiment, the notch 718 is defined between a pairof side walls 720 that extend from proximal surfaces 722 of the anteriorflange 712 and condyles 714, 716. A proximal wall 724 extends betweenthe side walls 720 to enclose the proximal end of the notch 718. Thefemoral trial component 20 also includes a boss 726 that extends fromthe proximal wall 724, which is configured to receive an offset adaptor770.

The boss 726 includes a planar proximal surface 728, and a pair ofalignment pins 730 extend outwardly from the surface 728. A bore 732extends through the boss 726 and opens into the intercondylar notch 718.The bore 732 is sized to permit a fastener such as, for example, bolt734 to pass through the femoral trial component 20 and engage the offsetadaptor 770. In that way, the femoral trial component 20 and the offsetadaptor 770 may be secured together via the bolt 734.

In the illustrative embodiment, the boss 726 extends along alongitudinal axis 740, and the proximal wall 724 of the femoralcomponent 16 includes a substantially planar surface 742. When thefemoral component 16 is viewed in a coronal plane, a non-orthogonalangle is defined between the axis 740 and the substantially planarsurface 742. It should be appreciated that the magnitude of the anglemay vary in various embodiments and based on the size and configurationof the prosthesis assembly.

As shown in FIG. 14, the trial system 710 also includes a stem component750. The stem component 750 includes an elongated body 752 that extendsfrom a proximal tip 754 to a distal end 756. A plurality of threads 758are defined on the distal end 756.

The trial system 710 also includes an offset adaptor 770 that isconfigured to be secured to the femoral trial component 20 and the stemcomponent 750 to form an offset femoral trial construct 772. The offsetadaptor 770 includes a two-piece body 774 that extends from a distal end776 to a proximal end 778 that is offset from the distal end 776, asshown in FIG. 14. In the illustrative embodiment, the body 774 includesa distal sleeve 780 that extends from the distal end 776 to a proximalsleeve 782. The proximal sleeve 782 is rotatively coupled to the distalsleeve 780 to permit the surgeon to adjust the orientation of thefemoral trial component 20 relative to the stem component 750 to findthe optimum position on the patient's bone for the femoral offsetprosthesis 662. The distal sleeve 780 includes a passageway 784 thatextends inwardly from the distal end 776 to a threaded aperture (notshown) in the proximal sleeve 782. The threaded aperture is sized toreceive the threaded end of the bolt 734 to secure the adaptor 770 tothe femoral trial component 20. As shown in FIG. 14, the proximal sleeve782 also includes a curved tapered surface 786 that connects the widerbase of the proximal sleeve 782 to the more narrow proximal end 778.

The body 774 also includes an opening 790 that is defined in theproximal end 778. A threaded inner wall 792 extends inwardly from theopening 790 to define a threaded bore 794 sized to receive the threadeddistal end 756 of the stem component 750. As shown in FIG. 14, theoffset adaptor 770 defines a proximal axis 796 that extends through thethreaded bore 794 and along the longitudinal axis of the stem component750. The offset adaptor 770 also defines a distal axis 798 that isaligned with the longitudinal axis 740 of the boss 726 of the femoraltrial component 20. The axes 796, 798 extend parallel to, but are offsetfrom, one another by the same amount as the axes 686, 688 in theprosthesis assembly 662.

Referring now to FIG. 15, the femoral trial system 710 also includes afemoral broach 800 that has a plurality of cutting teeth 802 configuredto remove portions of the patient's bone to prepare the bone to receivethe femoral sleeve component 628. The cutting teeth 802 are formed in astepped outer wall 804 having a configuration that corresponds to thestepped outer wall 690 of the femoral sleeve component 628. The broach800 has an opening 806 defined in its proximal end 808 and a threadedinner wall 810 shaped to receive the threaded distal end 756 of the stemcomponent 750. In the illustrative embodiment, the broach 800 includes adistal opening sized to receive the pins 730 of the femoral trialcomponent 20. The broach 800 also includes threads (not shown)configured to engage the threaded end of the bolt 734 to secure thebroach 800 to the femoral trial component 20.

Referring now to FIG. 16, a tibial orthopaedic prosthesis system 900includes the prosthetic tibial component 18 that is configured to beattached to a surgically-prepared proximal end of a patient's tibia. Thetibial component 18 includes a tibial tray 902 configured to receive apolymer insert or bearing (not shown) for articulation with the condyles604, 606 of the prosthetic femoral component 602. The tray 902 includesa platform 904 and a distal stem post 906 extending from the platform904. A pair of keels 908 extend between the outer surface 910 of thedistal stem 906 and the platform 904. The platform 904 has a planarproximal surface 912 positioned opposite the distal stem post 906 andkeels 908. The tibial tray 902 also includes a posterior buttress 914that extends outwardly from the planar proximal surface 912. In theillustrative embodiment, the posterior buttress 914 is Y-shaped. Thetibial tray 902 also includes an anterior buttress 916 that is spacedapart from the posterior buttress 914, as shown in FIG. 16.

The stem post 906 extends to a distal end 918. An opening 920 is definedin the distal end 918, and a passageway 922 extends inwardly from theopening 920. In the illustrative embodiment, threads (not shown) linethe distal part of the passageway 922. The stem post 906 extends along alongitudinal axis 930. As shown in FIG. 16, the stem post 906 is sizedto enter a patient's intramedullary canal, and the platform 904 is sizedto be positioned over the opening of the canal and engage the proximalsurface of the patient's tibia. The platform 904 includes a curved outerwall 932 that has a convex anterior section 934 and a concave posteriorsection 936 defined between to convex sections 938. The geometry of thecurved outer wall 932 is shaped to conform to the geometry of thesurgically-prepared proximal surface of the patient's tibia.

As shown in FIG. 16, the prosthesis system 900 also includes a stemcomponent 940. The stem component 940 includes an elongated body 942that extends from a proximal end 944 to a distal tip 946. A plurality ofthreads 948 are defined on the proximal end 944, which, in someconfigurations of the prosthesis assembly, may engage the threads inpassageway 922 of the post 906 of the tibial tray 902.

The prosthesis system 900 also includes an offset adaptor 960 that isconfigured to be secured to the tibial component 18 and the stemcomponent 940 to form an offset tibial prosthesis assembly 962. Theoffset adaptor 960 includes a body 964 that extends from a distal end966 to a proximal end 968 that is offset from the distal end 966, asshown in FIG. 16. The body 964 includes a threaded shaft 970 thatextends proximally from the proximal end 968 to a rim wall 972. The body964 also includes a curved tapered surface 974 extends distally from therim wall 972. The threaded shaft 970 is configured to engage the threadsin passageway 922 of the post 906 to attach the adaptor 960 to thetibial component 18. The offset adaptor 960 also includes a locking nut976 that is threaded onto the shaft 970, which may be operated to securethe offset adaptor 960 to the tibial component 18, as described ingreater detail below.

The body 964 also includes an opening 980 that is defined in the distalend 966. A bore 982 extends inwardly from the opening 980 and is sizedto receive the threaded proximal end 944 of the stem component 940. Aplurality of threads extend into the bore 982 and are configured toengage the threads 944 of the stem component 940. As shown in FIG. 16,the offset adaptor 960 defines a distal axis 986 that extends throughthe threaded bore 984 and along the longitudinal axis of the stemcomponent 940. The offset adaptor 960 also defines a proximal axis 988that extends through the threaded shaft 970 and is aligned with thelongitudinal axis 930 of the post 906 of the tibial component 18. Theaxes 986, 988 extend parallel to, but are offset from, one another. Inthe illustrative embodiment, the body 964 is a single monolithiccomponent such that the distal end 966 and the proximal end 968 arefixed relative to one another.

Referring now to FIG. 17, a tibial trial system 1000 includes the tibialtrial component 22 that is configured to be temporarily attached to theproximal end of a patient's tibia to assist with the surgicalpreparation of the patient's tibia to receive the prosthetic tibialcomponent 18. The tibial trial component 22 includes a base 1002 and astem post 1004 extending distally from the base 1002. The base 1002 isconfigured to receive a tibial insert trial (not shown), whicharticulates with the condyles 714, 716 of the femoral trial 20. As shownin FIG. 17, the stem post 1004 is sized to enter a patient'sintramedullary canal, and the base 1002 is sized to be positioned overthe opening of the canal and engage the proximal surface of thepatient's tibia. The base 1002 includes a curved outer wall 1006 thathas a convex anterior section 1008 and a concave posterior section 1016defined between to convex sections 1010. The geometry of the curvedouter wall 1006 is shaped to match of the outer wall 932 of the tibialtray 902 such that the surgeon may utilize the trial 22 to confirm thetibial tray is the appropriate for the patient. The tibial trial 22 alsoincludes a pair of alignment tabs 1018 that extend from the base 1002.

In the illustrative embodiment, the tibial trial component 22 alsoincludes a retained bolt 1012 that is rotatively coupled to the base1002. The bolt 1012 outwardly from the post 1004 along a longitudinalaxis 1014.

As shown in FIG. 17, the trial system 1000 also includes a stemcomponent 1020. The stem component 1020 includes an elongated body 1022that extends from a distal tip 1024 to a proximal end 1026. A pluralityof threads 1028 are defined on the proximal end 1026.

The trial system 1000 also includes an offset adaptor 1030 that isconfigured to be secured to the tibial trial component 22 and the stemcomponent 1020 to form an offset tibial trial construct 1032. The offsetadaptor 1030 includes a two-piece body 1034 that extends from a proximalend 1036 to a distal end 1038 that is offset from the proximal end 1036,as shown in FIG. 17. In the illustrative embodiment, the body 1034includes a proximal sleeve 1040 that extends from the proximal end 1036to a distal sleeve 1042. The distal sleeve 1042 that is rotativelycoupled to the proximal sleeve 1040 to permit the surgeon to adjust theorientation of the tibial trial component 22 relative to the stemcomponent 1020 to find the optimum position on the patient's bone forthe tibial offset prosthesis 962. The proximal sleeve 1040 includes apassageway 1044 that extends inwardly from the proximal end 1036 to athreaded aperture (not shown) in the distal sleeve 1042. The threadedaperture is sized to receive the threaded end of the bolt 1012 to securethe adaptor 1030 to the tibial trial component 22. As shown in FIG. 17,the distal sleeve 1042 also includes a curved tapered surface 1046 thatconnects the wider base of the distal sleeve 1042 to the more narrowdistal end 1038.

The body 1034 also includes an opening 1050 that is defined in thedistal end 1038. A bore 1052 extends inwardly from the opening 1050. Thebore 1052 is sized to receive the proximal end 1026 of the stemcomponent 1020. A plurality of threads (not shown) are formed along thebore 1052 and are sized to engage the threads formed on the proximal end1026 of the stem component 1020.

As shown in FIG. 17, the offset adaptor 1030 defines a distal axis 1060that extends through the threaded bore 1052 and along the longitudinalaxis of the stem component 1020. The offset adaptor 1030 also defines aproximal axis 1062 that is aligned with the longitudinal axis 1014 ofthe stem post 1004 of the trial 22. The axes 1060, 1062 extend parallelto, but are offset from, one another by the same amount as the axes 986,988 in the prosthesis assembly 962.

Referring now to FIGS. 18-20, the system 10 also includes a sleeveimpactor 1090 for use in securing the femoral sleeve component 628 tothe femoral component 16 is shown. The instrument 1090 is a singlemonolithic component formed from a metallic material such as, forexample, stainless steel that can be autoclaved and sterilized forrepeated use. The instrument 1090 includes an elongated body 1092 thatextends from a femoral impaction end 1094 to a tibial impaction end1096. In the illustrative embodiment, the femoral impaction end 1094 hasan aperture 1098 defined in a surface 1100, as shown in FIGS. 18 and 20.The aperture 1098 is sized to be positioned over the proximal end 694 ofthe sleeve component 628. The aperture 1098 is oblong and oval in shapein the illustrative embodiment.

As shown in FIG. 19, the tibial impaction end 1096 has an aperture 1102defined in a surface 1104. The aperture 1102 is sized to be positionedover the distal end 1292 of a tibial sleeve component 1286 (see FIG.46), as described in greater detail below. The aperture 1102 is circularin shape in the illustrative embodiment and provides clearance withrespect to the tibial base. The elongated body 1092 also has a pair ofopposing planar surfaces 1106, 1108 to assist with supporting theinstrument 1090 on the end of each sleeve component and prevent theinstrument from rolling.

As described above, the orthopaedic surgical instrument system 10 may beused in a surgical procedure to assemble the prosthetic componentsdescribed above in regard to FIGS. 12-17. FIGS. 21-47 illustrate varioussteps of a process for assembling an offset femoral prosthesis assembly662 (FIGS. 21-32, a process for assembling a femoral sleeve prosthesisassembly 704 (FIGS. 34-37), and a process for assembling an offsettibial prosthesis assembly 962 (FIGS. 38-43). It should be appreciatedthat the processes and steps described are exemplary only and do notexclude additional steps consistent with this disclosure. Additionally,all of the steps are shown in reference to prostheses for use on onlyone knee of the patient; it should be appreciated that similar steps maybe followed to assemble a prosthesis for the other knee.

During a surgical procedure, a surgeon may use a variety of cuttingguide blocks, cutting tools, and other instruments to surgically preparethe patient's bones to receive, initially, the trial constructs 772,1032. With the trial constructs attached to the patient's bones, thesurgeon may analyze the fit of the trial constructs 772, 1032 on thepatient's bones. The surgeon may also perform a trial reduction toevaluate the range of motion with an insert trial positioned between theconstructs. In that way, the surgeon may determine the size of thetibial and femoral prostheses for implantation into the patient's bone,as well as determine the desired orientation and position of the tibialand femoral prosthetic components relative to their respective stemcomponents.

During the trialing portion of the surgical procedure, the surgeon mayrotate the femoral trial component 20 relative to the proximal axis 796(and hence the stem component 750) of the offset adaptor 770. To do so,the distal sleeve 780 of the offset adaptor 770 is permitted to rotaterelative to the proximal sleeve 782, which is fixed with the stemcomponent 750 in the intramedullary canal of the patient's femur. Whenthe surgeon determines that the femoral trial component 20 is properlypositioned on the patient's femur, the surgeon may operate the bolt 734to lock the distal sleeve 780 in position relative to the proximalsleeve 782, thereby locking the femoral trial component 20 in a desiredorientation and position relative to the stem component 750.

Similarly, the surgeon may rotate the tibial trial component 22 relativeto the distal axis 1060 (and hence the stem component 1020) of theoffset adapter 1030 to change the position of the component 22 on theproximal end of the patient's tibia. To do so, the proximal sleeve 1040of the offset adaptor 1030 is permitted to rotate relative to the distalsleeve 1042, which is fixed with the stem component 1020 in theintramedullary canal of the patient's tibia. When the tibial trialcomponent 22 is properly positioned on the patient's tibia, the surgeonmay operate the bolt 1012 to lock the proximal sleeve 1040 in positionrelative to the distal sleeve 1042, thereby locking the tibial trialcomponent 22 in a desired orientation and position relative to the stemcomponent 1020.

Referring now to FIGS. 21-32, the surgeon or other user may use theinstrument system 10 to assemble an offset femoral prosthesis assembly662 based on the configuration of the femoral trial construct 772created as described above. In other words, the surgeon may utilize theinstrument system 10 to secure the prosthetic femoral component 16 tothe stem component 640 in a position and orientation that matches thedesired orientation and position of the femoral trial component 20determined during the surgical procedure. In that way, the assembledoffset femoral prosthesis 662 replicates and matches the configurationof the femoral trial construct 772.

To do so, the user may attach the appropriate modular instruments 14 tothe instrument base 12, including the support arm assembly 36 and thefemoral trial carrier 30. As shown in FIG. 21, the user may align themounting shaft 126 of the support arm assembly 36 with the centralpassageway 124 defined in the mounting post 52 of the instrument base12. Additionally, the alignment tab 130 of the support arm assembly 36is aligned with the upper end of the alignment slot 128. The user maythen advance the mounting shaft 126 into the central passageway 124 andthe alignment tab 130 into the alignment slot 128. As the tab 130advances downward and along the alignment slot 128, the elongated arm258 is pivoted relative to the mounting post 52. When properlypositioned on the mounting post 52, the elongated arm 258 is alignedwith the vertically-extending orientation plane 270, as shown in FIG.21.

To attach the femoral trial carrier 30 to the instrument base 12, theuser may align the orientation holes 320, 322 with the cylindrical pin104 and the polygonal pin 106, respectively, on the base platform 42.The user may then advance the carrier 30 over the pins 104, 106 toposition the mounting block 330 of the carrier 30 on the platform 42.When the locking mechanism 56 is in the unlocked position, the user mayrotate the platform 42 (and hence the femoral trial carrier 30) aboutthe axis 38 to position the femoral trial carrier 30 as shown in FIG.22.

Referring now to FIGS. 22-23, the user may mount the femoral trialconstruct 772 on the femoral trial carrier 30. To do so, the user mayposition the femoral trial construct 772 over the alignment pin 352 andthe post 332 of the femoral trial carrier 30. As shown in FIG. 23, theuser aligns the distal opening 1200 of the bore 732 defined in thefemoral trial component 20 with the alignment pin 352. The user mayadvance the femoral trial construct 772 downward such that the pin 352and the upper end of the post 332 are received in the bore 732. The pin352 is advanced into the socket (not shown) of the bolt 734 of theconstruct 772, and the wall 364 is positioned in the intercondylar notch718 of the femoral trial component 20. As shown in FIG. 22, the surgicalinstrument system 10 also includes a support shim 1202 that ispositioned on the wall 364 and is sized to be positioned theintercondylar notch 718 to support femoral trial component 20 on thecarrier 30.

Returning to FIG. 6, the shim 1202 is shown in greater detail. The shim1202 includes a body 1204 that extends from an end surface 1206 to anopposite end surface 1208 along a longitudinal axis 1210. The body 1204has a lower opening 1212, which extends from the surface 1206 to thesurface 1208 along the axis 1210. The shim 1202 includes a pair of innerside walls 1214, 1216 that extend upwardly from the opening 1212 to acurved base wall 1218. The walls 1214, 1216, 1218 define a channel 1220in the shim 1202 that is sized to receive the walls 362, 364 of thecarrier 30. In the illustrative embodiment, the shim 1202 also includesa groove 1222 defined in the side wall 1214. The groove 1222 is sized toreceive the ribs 370 of the carrier 30 such that the shim 1202 may bemounted to each of the walls 362, 364 in only a single orientation.

The shim 1202 is formed from a material such as polymer in theillustrative embodiment. It has a width or thickness 1230 definedbetween a pair of planar side surfaces 1232. Returning to FIG. 23, thethickness 1230 of the shim 1202 is equal to about the width 1234 of theintercondylar notch 718. The width 1234 is defined between the sidewalls 720 of the femoral trial 20. It should be appreciated that thesystem 10 includes multiple shims of different thicknesses correspondingto different sizes of the femoral trial components 20 and prostheticfemoral components 16.

As shown in FIG. 24, the femoral trial construct 772 is positioned onthe carrier 30 and the shim 1202. In that position, the axis 740 of thefemoral trial component 20 and the axes 796, 798 defined by the offsetadaptor 770 extend parallel to the axis 38 of the instrument base 12. Asshown in FIG. 26, which is a cross-sectional view taken along the line26-26 in FIG. 24, the post 332 and the alignment pin 352 also extendparallel to those axes. In the illustrative embodiment, thenon-orthogonal angle 1236 defined between the wall 364 and the mountingblock 330 of the carrier 30 is equal to non-orthogonal angle 1238defined between the planar surface 742 and the axis 740 of the femoraltrial component 20 to position the axes 740, 796, 798 parallel to theaxis 38 of the base 12.

With the femoral trial construct 772 on the femoral trial carrier 30,the assembly may be rotated in either direction shown by arrow 1240 inFIG. 24 to orient the femoral trial construct 772 relative to thesupport arm assembly 36. In the illustrative embodiment, the femoraltrial construct 772 is rotated to position the axes 740, 796, 798 in thevertically-extending orientation plane 270 defined by the axis 38 andthe axis 260 of the support arm assembly 36. Additionally, the axis 798is positioned between the axis 796 and the support arm assembly 36 inthe orientation plane 270 such that the proximal sleeve 782 ispositioned closer to the arm assembly 36 than the distal sleeve 780 ofthe offset adaptor 770. When properly positioned, the user may advancethe tip 264 of the support arm assembly 36 along the axis 260 toward thefemoral trial construct 772, as indicated by arrow 1242 in FIG. 24.

As shown in FIG. 25, the shafts 278, 280 advance over the femoral trialconstruct 772 to position the offset adaptor 770 in the proximal end 288of the channel 282 of the support arm 36. The user may confirm that thefemoral trial construct 772 is properly oriented by checking that thetapered surface 786 of the offset adaptor 770 faces away from the arm 36and is aligned with the chamfered end walls 284 of the shafts 278, 280.In some embodiments, as shown in FIG. 26, the user may confirm thefemoral trial construct 772 is properly oriented by checking that avisual indicia such as, for example, line 1244 defined on the offsetadaptor 770 faces toward the arm 36 and is aligned with the channel 282.

Returning to FIG. 25, the user may operate the tightening mechanism 300to secure the femoral trial construct 772 to the support arm 36. To doso, the user may rotate the knob 302 about its axis to thread theelongated shaft 304 into the threaded bore 308 and draw the shafts 278,280 closer together. As the shafts 278, 280 move closer, the channel 282becomes more narrow, and the shafts 278, 280 engage the offset adaptor770.

The user may operate the locking mechanism 56 to lock the platform 42 inposition relative to the arm 36 and the housing 40 of the base 12. To doso, the user may grasp the grip 146 of the knob 140 and rotate the knob140 in the direction indicated by arrow 224 in FIG. 25. As the knob 140is rotated, the clutch 170 of the locking mechanism 56 is rotated toadvance the teeth 202 into engagement with the teeth 102 of the platform42, thereby locking the platform 42 in position relative to the housing40. The instrument base 12 is now able to replicate the position andorientation of the femoral trial construct 772 and is ready to beginassembly of the offset femoral prosthesis 600.

The user may operate the tightening mechanism 300 to disengage theshafts 278, 280 from the offset adaptor 770. The support arm 36 may bemoved away from the femoral trial construct 772 such that the femoraltrial construct 772 may be detached from the carrier 30. The user alsodetaches the carrier 30 from the instrument base 12. Throughout, theknob 140 (and hence the locking mechanism 56) remains in the lockedposition such that the platform 42 is prevented from rotating relativeto the housing 40.

Referring now to FIG. 28, the user may attach the femoral prosthesiscarrier 32 to the platform 42 by positioning the holes 320, 322 over theappropriate pins 44 of the platform 42 in a manner similar to thatdescribed above for the femoral trial carrier 30. The user may slide thesame support shim 1202 onto the wall 464 of the carrier 32, as shown inFIG. 28. A prosthetic femoral component 16 corresponding to the femoraltrial component 20 may be aligned with the post 432 of the carrier 32and advanced over the post 432 to position the component 16 as shown inFIGS. 29-30.

As shown in FIG. 31, which is a cross-sectional view taken along theline 31-31 in FIG. 29, the post 432 is received in the proximal openingof the bore 622 of the femoral component 16. In the illustrativeembodiment, the non-orthogonal angle 1246 defined between the wall 464and the mounting block 430 of the carrier 32 that is equal to anon-orthogonal angle 1248 defined between the planar surface 632 and theaxis 630 of the femoral component 16, which position the axis 630parallel to the axis 38 of the base 12 and in the orientation plane 270.As described above, the carrier 32 includes the section 476, whichreduces the thickness of the block 430 on one side. As shown in FIG. 31,this reduced thickness maintains a gap 1252 between the block 430 andthe condyle 606 of the femoral component 16.

Returning to FIG. 29, the user may attach the offset adaptor 660 to thefemoral component 16. To do so, the user may align the threaded shaft670 with the post 616 of the femoral component 16 and advance thethreaded shaft 670 into the bore 622. The shaft 670 is rotated about itsaxis 686 to advance the locking nut 676 (which is seated against the rimwall 672 of the adaptor 660) into contact with the post 616. With thelocking nut 676 seated on the post 616, the user may rotate the proximalend 668 of the adaptor 660 about the axis 686 to orient the curvedtapered surface 674 away from the support arm assembly 36, as shown inFIG. 30. In that position, the axes 630, 686, 688 are positioned in thevertically-extending orientation plane 270. Additionally, the axis 686is positioned between the axis 688 and the support arm assembly 36 inthe orientation plane 270 such that the proximal end 668 of the offsetadaptor 660 is positioned closer to the arm assembly 36 than the distalend 666.

The user may position the offset adaptor 660 in the channel 282 of thesupport arm 36 by advancing the tip 264 of the arm toward the offsetadaptor 660. With the adaptor 660 positioned in the channel 282, theuser may operate the tightening mechanism 300 to secure the offsetadaptor 660 to the support arm 36. To do so, the user may rotate theknob 302 about its axis to thread the elongated shaft 304 into thethreaded bore 308 and draw the shafts 278, 280 closer together. As theshafts 278, 280 move closer, the channel 282 becomes more narrow, andthe shafts 278, 280 engage the offset adaptor 660, as shown in FIG. 30.

With the offset adaptor 660 retained in the support arm assembly 36, theuser may use a torque wrench (not shown) to tighten the locking nut 676against the post 616 to add a preload to the components 16, 660. In theillustrative embodiment, the preload places the threaded section 624 ofthe post 616 and the thread shaft 670 in tension, thereby securing thecomponent 16 to the offset adaptor 660.

Referring now to FIG. 32, the user may select a stem component 640 forthe prosthesis 662 based on the configuration (e.g., length) of the stemcomponent 750. The user may then secure the stem component 640 to theproximal end 668 of the offset adaptor 660 by threading the distal end644 of the stem component 640 into the threaded bore 684 of the proximalend 668. The user may use a torque wrench (not shown) to tighten thestem component 640 against the offset adaptor 660 to add a preload tothe components 640, 660 and form the offset prosthesis 662. In this way,the orientation and positioning of the offset trial construct 772 isreplicated in the offset prosthesis 662. The user may then detach thesupport arm assembly 36 from the prosthesis 662 and remove theprosthesis 662 from the carrier 32 for implantation into the patient'sfemur.

As shown in FIG. 33, the instrument base 12, the carrier 32, and otherinstruments of system 10 may be used to assemble a straight stem femoralprosthesis 1250. In the illustrative embodiment, the straight stemfemoral prosthesis 1250 includes the femoral component 16 and a stemcomponent 640, which is secured to the post 616 of the femoral component16. As shown in FIG. 33, the femoral component 16 is mounted to the base12 in a manner similar to that described above. It should be appreciatedthat the support arm 36 is advanced over the stem component 640 andoperated to constrain the stem component 640 during torqueing asdescribed above.

Referring now to FIGS. 34-37, the carrier 32 and the sleeve impactor1090 may be used to assemble a femoral sleeve prosthesis assembly 704.To do so, the femoral component 16 is mounted on the carrier 32 and theshim 1202 as shown in FIG. 34 in a manner similar to that describedabove. The sleeve component 628 may then be advanced over the post 616of the femoral component 16. As shown in FIG. 35, the post 616 isreceived in an opening defined in the distal end 692. As describedabove, the distal opening is defined by a tapered inner surface thatcorresponds to the tapered outer surface 626 of the post 616 such thatthe sleeve component 628 may be secured to the post 616 via a taperlock.

To create the taper lock, the user may utilize the sleeve impactor 1090to engage the proximal end 694 of the sleeve component 628. As shown inFIG. 36, the proximal end 694 of the sleeve component 628 is positionedin the aperture 1098 defined in the femoral impaction end 1094. The usermay use a mallet or other instrument to tap on the tibial impaction end1096 to advance the sleeve component 628 along the post 616 and createthe taper lock.

As described above, the sleeve component 628 is configured to be securedto a stem component 640. To do so, the threaded distal end 646 of thestem component 640 is threaded into the threaded bore 650 defined in theproximal end 694 of the sleeve component 628. The user may use a torquewrench (not shown) to tighten the stem component 640 against the sleevecomponent 628 to add a preload to the components 628, 640 and form thesleeve prosthesis assembly 704.

To hold sleeve component 628 in position while applying torque to thestem component 640, the user may utilize the wrench 1260 shown in FIG.37. The wrench 1260 includes an elongated handle 1262 and a head 1264attached to the handle 1262. The head 1264 includes a pair of arms 1266,1268 that defined a slot 1270 sized to receive the proximal end 694 ofthe sleeve component 628. Each arm 1266, 1268 includes a plurality ofsurfaces 1274 that define the slot 1270 and a plurality of lobes 1272that extend from the surfaces 1274 into the slot 1270. Each lobe 1272 isrounded and configured to the flat surfaces (as opposed to the edges) ofthe proximal end 694 of the sleeve 628.

As described above, during surgery, the surgeon may position a tibialtrial construct 1032 on a patient's tibia and rotate the tibial trialcomponent 22 relative to the distal axis 1060 (and hence the stemcomponent 1020) of the offset adapter 1030 to change the position of thetrial component 22 on the proximal end of the patient's tibia. When thetibial trial component 22 is properly positioned on the patient's tibia,the surgeon may operate the bolt 1012 to lock the proximal sleeve 1040of the offset adaptor 1030 in position relative to the distal sleeve1042, thereby locking the tibial trial component 22 in a desiredorientation and position relative to the stem component 1020.

Referring now to FIGS. 38-43, the instrument system 10 may be used toassemble an offset tibial prosthesis assembly 962 based on theconfiguration of the tibial trial construct 1032 created as describedabove. In other words, the surgeon may utilize the instrument system 10to secure the prosthetic tibial component 18 to the stem component 940in a position and orientation that matches the desired orientation andposition of the tibial trial component 22 determined during the surgicalprocedure. In that way, the assembled offset tibial prosthesis 962replicates and matches the configuration of the tibial trial construct1032.

To do so, the user may attach the appropriate modular instruments 14 tothe instrument base 12, including the support arm assembly 36 and thetibial component carrier 34. To attach the tibial component carrier 34to the instrument base 12, the user may align the orientation holes 320,322 with the cylindrical pin 104 and the polygonal pin 106,respectively, on the base platform 42, as shown in FIG. 38. The user maythen advance the carrier 34 over the pins 104, 106 to position themounting block 500 of the carrier 34 on the platform 42. When thelocking mechanism 56 is in the unlocked position, the user may rotatethe platform 42 (and hence the carrier 34) about the axis 38 to positionthe carrier 34 as shown in FIG. 39.

The user may position the tibial trial construct 1032 on the carrier 34,as shown in FIG. 39. In the illustrative embodiment, the stem component1020 of the construct 1032 has been detached for ease of viewing. Itshould be appreciated that the stem component 1020 may be attachedduring each of the steps described below. To attach the construct 1032to the carrier 34, the user aligns the tabs 1018 of the trial 22 withthe Y-shaped channel 560 defined in the clamp plate 504. The user maythen move the base 1002 of the trial 22 into contact with the pads 556,558 of the clamp plate 504. As shown in FIG. 39, the inner wall 566 ofthe jaw 562 is positioned between the posterior sections 1010 and in theconcave posterior section 1016. The anterior wall section 1008 faces thejaw 542 of the carrier 34. The user may then utilize the knob 580 toadvances the jaw 542, 562 toward each other and clamp the base 1002between them.

As shown in FIG. 39, the tibial trial construct 1032 is positioned onthe carrier 34. In that position, the axes 1014, 1060, 1062 extendparallel to the axis 38 of the instrument base 12. With the tibial trialconstruct 1032 on the carrier 34, the assembly may be rotated in eitherdirection shown by arrow 1240 to orient the tibial trial construct 1032relative to the support arm assembly 36. In the illustrative embodiment,the tibial trial construct 1032 is rotated to position the axes 1014,1060, 1062 in the vertically-extending orientation plane 270.Additionally, the axis 1062 is positioned between the axis 1060 and thesupport arm assembly 36 in the orientation plane 270 such that thedistal sleeve 1042 is positioned closer to the arm assembly 36 than theproximal sleeve 1040 of the offset adaptor 1030. When properlypositioned, the user may advance the tip 264 along the axis 260 towardthe tibial trial construct 1032, as indicated by arrow 1242.

As shown in FIG. 40, the shafts 278, 280 advance over the tibial trialconstruct 1032 to position the offset adaptor 1030 in the proximal end288 of the channel 282 of the support arm 36. The user may confirm thatthe tibial trial construct 1032 is properly oriented by checking thatthe tapered surface 1046 of the offset adaptor 1030 faces away from thearm 36 and is aligned with the chamfered end walls 284 of the shafts278, 280. In some embodiments, the user may confirm the tibial trialconstruct 1032 is properly oriented by checking that a visual indiciadefined on the offset adaptor 1030 faces toward the arm 36 and isaligned with the channel 282.

The user may operate the tightening mechanism 300 to secure the tibialtrial construct 1032 to the support arm 36. To do so, the user mayrotate the knob 302 about its axis to thread the elongated shaft 304into the threaded bore 308 and draw the shafts 278, 280 closer together.As the shafts 278, 280 move closer, the channel 282 becomes more narrow,and the shafts 278, 280 engage the offset adaptor 1030. The user mayalso operate the locking mechanism 56 to lock the platform 42 inposition relative to the arm 36 and the housing 40 of the base 12. To doso, the user may grasp the grip 146 of the knob 140 and rotate the knob140 in the direction indicated by arrow 224 in FIG. 40.

With the platform 42 prevented from rotating, the user may operate thetightening mechanism 300 to disengage the shafts 278, 280 from theoffset adaptor 1030. The support arm 36 may be moved away from thetibial trial construct 1032 such that the tibial trial construct 1032may be detached from the carrier 34.

A prosthetic tibial component 18 such as tray 902 corresponding to thetibial trial component 22 may be attached to the carrier 34 in place ofthe tibial trial construct 1032, as shown in FIG. 41. To do so, the useraligns the Y-shaped buttress 914 of the tray 902 with the Y-shapedchannel 560 defined in the clamp plate 504. The user may then move theplatform 904 of the tibial tray 902 into contact with the pads 556, 558of the clamp plate 504. As shown in FIG. 39, the inner wall 566 of thejaw 562 is positioned between the posterior sections 938 and in theconcave posterior section 936. The anterior wall section 934 faces thejaw 542 of the carrier 34. The user may then utilize the knob 580 toadvances the jaw 542, 562 toward each other and clamp the tibial tray902 between them.

Referring now to FIG. 42, the user may attach the offset adaptor 960 tothe tibial tray 902. To do so, the user may align the threaded shaft 970with the post 906 of the tibial tray 902 and advance the threaded shaft970 into the bore 922. The shaft 970 is rotated about its axis 988 toadvance the locking nut 976 (which is seated against the rim wall 972 ofthe adaptor 960) into contact with the post 906. With the locking nut976 seated on the post 906, the user may rotate the distal end 966 ofthe adaptor 960 about the axis 988 to orient the curved tapered surface974 away from the support arm assembly 36, as shown in FIG. 42. In thatposition, the axes 930, 986, 988 are positioned in thevertically-extending orientation plane 270. Additionally, the axis 988is positioned between the axis 986 and the support arm assembly 36 inthe orientation plane 270 such that the distal end 966 of the offsetadaptor 960 is positioned closer to the arm assembly 36 than the distalend 666.

The user may position the offset adaptor 960 in the channel 282 of thesupport arm 36 by advancing the tip 264 of the arm toward the offsetadaptor 960. With the adaptor 960 positioned in the channel 282, theuser may operate the tightening mechanism 300 to secure the offsetadaptor 960 to the support arm 36. To do so, the user may rotate theknob 302 about its axis to thread the elongated shaft 304 into thethreaded bore 308 and draw the shafts 278, 280 closer together. As theshafts 278, 280 move closer, the channel 282 becomes more narrow, andthe shafts 278, 280 engage the offset adaptor 960, as shown in FIG. 43.

With the offset adaptor 960 griped by the support arm assembly 36, theuser may use a torque wrench (not shown) to tighten the locking nut 976against the post 906 to add a preload to the components 18, 960. In theillustrative embodiment, the preload places the threads in the bore 922of the post 616 and the threaded shaft 970 in tension, thereby securingthe component 18 to the offset adaptor 960.

The user may select a stem component 940 for the prosthesis 962 based onthe configuration (e.g., length) of the stem component 1020. The usermay then secure the stem component 940 to the distal end 966 of theoffset adaptor 960 by threading the proximal end 944 of the stemcomponent 940 into the threaded bore 982 of the adaptor 960. The usermay use a torque wrench (not shown) to tighten the stem component 940against the offset adaptor 960 to add a preload to the components 940,960 and form the offset prosthesis 962. In this way, the orientation andpositioning of the offset trial construct 1032 is replicated in theoffset prosthesis 962. The user may then detach the support arm assembly36 from the prosthesis 962 and remove the prosthesis 962 from thecarrier 34 for implantation into the patient's tibia.

As shown in FIGS. 44-47, the instrument base 12, the carrier 34, andother instruments of system 10 may be used to assemble a tibial sleeveprosthesis 1280. In the illustrative embodiment, the prosthesis 1280includes a tibial tray 1282 similar to the tibial tray 902, except for alonger and tapered stem post 1284, as shown in FIG. 44. The prosthesis1280 also includes a sleeve component 1286 configured to be positionedon the tapered stem post 1284, as shown in FIG. 45. The sleeve component1286 includes a stepped outer wall 1290 and a tapered inner wall (notshown) configured to secure the sleeve component 1286 to the tibial tray1282 via a taper lock.

As shown in FIG. 44, the tibial tray 1282 is mounted to the base 12using the carrier 34 in a manner similar to that described above. Itshould be appreciated that the support arm 36 is not necessary toassemble the tibial sleeve prosthesis 1280. With the tibial tray 1282positioned on the carrier 34, the sleeve component 1286 is advanced overthe post 1284, as shown in FIG. 45.

To create the taper lock, the user may utilize the sleeve impactor 1090to engage the distal end 1292 of the sleeve component 1286. As shown inFIG. 46, the distal end 1292 of the sleeve component 1286 is positionedin the aperture 1102 defined in the tibial impaction end 1096. The usermay use a mallet or other instrument to tap on the femoral impaction end1094 to advance the sleeve component 1286 along the post 1284 and createthe taper lock.

The post 1284 of the tibial tray 1282 is configured to be secured to astem component 940. To do so, the threaded proximal end 944 of the stemcomponent 940 is threaded into a threaded bore 1294 defined in thedistal end 1296 of the post 1284, as shown in FIG. 47. The user may usea torque wrench (not shown) to tighten the stem component 940 againstthe tibial tray 1282 to add a preload to the 940, 1282 and form thesleeve prosthesis assembly 1280.

While the disclosure has been illustrated and described in detail in thedrawings and foregoing description, such an illustration and descriptionis to be considered as exemplary and not restrictive in character, itbeing understood that only illustrative embodiments have been shown anddescribed and that all changes and modifications that come within thespirit of the disclosure are desired to be protected.

There are a plurality of advantages of the present disclosure arisingfrom the various features of the method, apparatus, and system describedherein. It will be noted that alternative embodiments of the method,apparatus, and system of the present disclosure may not include all ofthe features described yet still benefit from at least some of theadvantages of such features. Those of ordinary skill in the art mayreadily devise their own implementations of the method, apparatus, andsystem that incorporate one or more of the features of the presentinvention and fall within the spirit and scope of the present disclosureas defined by the appended claims.

The invention claimed is:
 1. A method of assembling an orthopaedicprosthesis, the method comprising: aligning a femoral trial constructwith a surgical instrument that includes a mounting platform and astabilizer arm, the femoral trial construct comprising a post thatdefines a first axis and an offset adaptor trial that defines a secondaxis that is offset from the first axis, positioning the femoral trialconstruct on the mounting platform, rotating the mounting platform toposition the first axis and the second axis in a plane extendingvertically through the stabilizer arm, advancing the stabilizer armalong the vertically-extending plane to engage the stabilizer arm withthe femoral trial construct, locking the mounting platform to preventrotation relative to the stabilizer arm, positioning a femoralprosthetic component on the mounting platform after removing the femoraltrial construct such that a third axis defined by a proximal post of thefemoral prosthetic component is positioned in the plane, positioning afemoral offset adaptor on the proximal post, the femoral offset adaptorincluding a proximal end that defines a fourth axis that is offset fromthe third axis, rotating the proximal end of the femoral offset adaptorto position the fourth axis in the vertically-extending plane, andsecuring the femoral offset adaptor to the femoral prosthetic componentwith the third axis and the fourth axis positioned in the plane.
 2. Themethod of claim 1, further comprising attaching a carrier to themounting platform, the carrier including a mounting plate and a firstpost extending upwardly from the mounting plate, wherein positioning thefemoral trial construct on the mounting platform comprises advancing thefemoral trial construct over the post to position the post in apassageway defined in the femoral trial construct.
 3. The method ofclaim 2, further comprising attaching to the carrier a shim sized to bepositioned in an intercondylar notch defined in the femoral trialconstruct, wherein positioning the femoral trial construct on themounting platform further comprises advancing the femoral trialconstruct over the shim to position the shim in the intercondylar notch,and wherein positioning the femoral trial construct on the mountingplatform includes preventing a pair of condyles of the femoral trialconstruct from engaging the mounting plate of the carrier.
 4. The methodof claim 3, further comprising: detaching the carrier from the mountingplatform, attaching a second carrier to the mounting platform, thesecond carrier including a second mounting plate and a second postextending upwardly from the second mounting plate, the second posthaving a configuration different from a configuration of the first post,and attaching the shim the second carrier.
 5. The method of claim 4,wherein positioning the femoral prosthetic component on the mountingplatform after removing the femoral trial construct includes: advancingthe femoral prosthetic component over the second post to position thesecond post in a passageway defined in the femoral prosthetic component,advancing the femoral prosthetic component over the shim to position theshim in an intercondylar notch of the femoral prosthetic component, andpreventing a pair of condyle surfaces of the femoral prostheticcomponent from engaging the second mounting plate of the second carrier.6. The method of claim 4, further comprising: determining whether thefemoral trial construct includes one of a first femoral trial componentconfigured to be attached to a left femur and a second femoral trialcomponent configured to be attached to a right femur, and selecting afemoral prosthetic component based on whether the femoral trialconstruct includes the first femoral trial component or the secondfemoral trial component, wherein attaching the second carrier to themounting platform includes orienting the second carrier on the mountingplatform based on the selected femoral prosthetic component, and whereinattaching the shim to the second carrier includes attaching the shim toone of a first wall of the second carrier positioned on a first side ofthe second post and a second wall of the second carrier positioned on asecond side of the second post based on the selected femoral prostheticcomponent.
 7. The method of claim 1, wherein positioning the femoralprosthetic component on the mounting platform includes orienting thefemoral prosthetic component such that the third axis extends at anorthogonal angle relative to the mounting platform, wherein the femoralprosthetic component includes a pair of condyles and a box structurethat connects the pair of condyles, the box structure including a planarproximal surface that extends at a non-orthogonal angle relative to thethird axis.
 8. The method of claim 1, further comprising securing a stemcomponent to the proximal end of the femoral offset adaptor.
 9. Themethod of claim 1, further comprising advancing the stabilizer arm alongthe vertically-extending plane to engage the stabilizer arm with theproximal end of the femoral offset adaptor after rotating the proximalend of the femoral offset adaptor to position the third axis in thevertically-extending plane.
 10. The method of claim 9, wherein advancingthe stabilizer arm along the vertically-extending plane to engage thestabilizer arm with the proximal end of the femoral offset adaptorincludes positioning the proximal end of the femoral offset adaptor in achannel defined between a pair of proximal tips of the stabilizer arm.11. The method of claim 10, wherein advancing the stabilizer arm alongthe vertically-extending plane to engage the stabilizer arm with theoffset adaptor trial includes positioning the offset adaptor trial inthe channel defined in the stabilizer arm.
 12. The method of claim 11,further comprising securing the offset adaptor trial in the proximal tipof the stabilizer arm before locking the mounting platform to preventrotation relative to the stabilizer arm.
 13. The method of claim 11,further comprising aligning a visual marking on the offset adaptor trialwith an alignment window defined in the stabilizer arm.
 14. The methodof claim 9, wherein advancing the stabilizer arm along thevertically-extending plane to engage the stabilizer arm with the offsetadaptor trial further includes aligning a pair of chamfered end surfacesof proximal tip with a sloped surface of the offset adaptor trial.
 15. Amethod of assembling an orthopaedic prosthesis, the method comprising:rotating a mounting platform of a surgical instrument about avertically-extending axis, attaching a carrier to the mounting platform,attaching a shim to the carrier, positioning a first femoral prostheticcomponent on the carrier, the first femoral prosthetic componentincluding a pair of spaced apart condyles, an intercondylar notch sizedto receive the shim, and a proximal post, and securing a second femoralprosthetic component to the proximal post of the first femoralprosthetic component, wherein the second femoral prosthetic componentincludes an offset adaptor and an elongated stem component configured tobe attached to a proximal end of the offset adaptor.
 16. The method ofclaim 15, wherein the second femoral prosthetic component includes anelongated stem component.
 17. The method of claim 15, wherein the secondfemoral prosthetic component includes a prosthetic sleeve having astepped outer surface.
 18. The method of claim 15, wherein: the proximalpost of the first femoral prosthetic component defines a first axis, andsecuring the second femoral prosthetic component to the post of thefirst femoral prosthetic component includes: rotating a proximal end ofthe offset adaptor to position a second axis defined by the proximal endin a vertically-extending plane, and securing the offset adaptor to theproximal post of the first femoral prosthetic component with the firstaxis and the second axis positioned in the vertically-extending plane.19. The method of claim 18, further comprising advancing a stabilizerarm of the surgical instrument along the vertically-extending plane toposition the stabilizer arm over the proximal end of the offset adaptorand securing the offset adaptor to the stabilizer arm.